Vehicle interior systems having a curved cover glass with improved reliability and methods for forming the same

ABSTRACT

Embodiments of a vehicle interior system are disclosed. In one or more embodiments, the system includes a base with a curved surface, a cold-formed glass substrate with a thickness of 1.5 mm or less and a first radius of curvature of 500 mm or greater, and an adhesive between the curved surface and the glass substrate. Methods for forming such systems are also disclosed. The systems and methods include components and/or design modifications or methods for reducing stress in the adhesive.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/754,853, filed on Apr. 9, 2020, which is a national stage applicationunder 35 U.S.C. § 371 of International Application No.PCT/US2018/055217, filed on Oct. 10, 2018, which claims the benefit ofpriority under 35 U.S.C. § 119 of U.S. Provisional Application Ser. No.62/570,430 filed on Oct. 10, 2017, the contents of which relied upon andincorporated herein by reference in their entirety.

BACKGROUND

The disclosure relates to vehicle interior systems including glass andmethods for forming the same, and more particularly to vehicle interiorsystems including a curved cover glass that is cold-formed or cold-bentwith improved reliability and methods for forming the same.

Vehicle interiors include curved surfaces, which can incorporatedisplays and/or touch panel in such curved surfaces. The materials usedto form such curved surfaces are typically limited to polymers, which donot exhibit the durability and optical performance as glass. As such,curved glass substrates are desirable, especially when used as coversfor displays and/or touch panel. Existing methods of forming such curvedglass substrates, such as thermal forming, have drawbacks including highcost, optical distortion, and surface marking. Accordingly, Applicanthas identified a need for vehicle interior systems that can incorporatea curved glass substrate in a cost-effective manner and without problemstypically associated with glass thermal forming processes. In addition,Applicant has identified a need for vehicle interior systems usingstructural adhesives while achieving improved product reliability andperformance, and decreased propensity for flaws to propagate throughareas of the adhesive having high stress levels.

SUMMARY

A first aspect of this disclosure pertains to a vehicle interior system.In one or more embodiments, the vehicle interior system includes a basehaving a curved surface, a cold-formed glass substrate disposed on thecurved surface, and an adhesive disposed between the curved surface andthe glass substrate. The glass substrate of one or more embodimentscomprises a first major surface, a second major surface opposing thefirst major surface and facing the curved surface, and a minor surfaceconnecting the first major surface and the second major surface. Theglass substrate further includes a thickness defined as a distancebetween the first major surface and the second major surface, a widthdefined as a first dimension of one of the first or second majorsurfaces orthogonal to the thickness, and a length defined as a seconddimension of one of the first or second major surfaces orthogonal toboth the thickness and the width, where the thickness is 1.5 mm or lessand the second major surface includes a first radius of curvature of 500mm or greater. According to one or more embodiments, the vehicleinterior system further includes at least one stress-reduction componentcoupled to the glass substrate in a location that reduces an amount ofadhesive stress in one or more areas of the adhesive.

A second aspect of this disclosure pertains to a vehicle interiorsystem. In one or more embodiments, the vehicle interior system includesa base having a curved surface, a cold-formed glass substrate disposedon the curved surface, and an adhesive disposed between the curvedsurface and the glass substrate. The glass substrate of one or moreembodiments comprises a first major surface, a second major surfaceopposing the first major surface and facing the curved surface, and aminor surface connecting the first major surface and the second majorsurface. The glass substrate further includes a thickness defined as adistance between the first major surface and the second major surface, awidth defined as a first dimension of one of the first or second majorsurfaces orthogonal to the thickness, and a length defined as a seconddimension of one of the first or second major surfaces orthogonal toboth the thickness and the width, where the thickness is 1.5 mm or lessand the second major surface includes a first radius of curvature of 500mm or greater. According to one or more embodiments, the base and/or thesecond major surface includes a second radius of curvature that isgreater than the first radius of curvature.

A third aspect of this disclosure pertains to a vehicle interior system.In one or more embodiments, the vehicle interior system includes a basehaving a curved surface, a cold-formed glass substrate disposed on thecurved surface, and an adhesive disposed between the curved surface andthe glass substrate. The glass substrate of one or more embodimentscomprises a first major surface, a second major surface opposing thefirst major surface and facing the curved surface, and a minor surfaceconnecting the first major surface and the second major surface. Theglass substrate further includes a thickness defined as a distancebetween the first major surface and the second major surface, a widthdefined as a first dimension of one of the first or second majorsurfaces orthogonal to the thickness, and a length defined as a seconddimension of one of the first or second major surfaces orthogonal toboth the thickness and the width, where the thickness is 1.5 mm or lessand the second major surface includes a first radius of curvature of 500mm or greater. According to one or more embodiments, the second majorsurface comprises a second area having a hot-formed curved surfaceincluding a second radius of curvature.

Another aspect of the disclosure pertains to a method of forming acurved vehicle interior component. The method includes hot-forming afirst area of a glass substrate having a first major surface and asecond major surface opposite the first major surface to a first radiusof curvature as measured on the second major surface, and cold-forming asecond area of the glass substrate to a second radius of curvature asmeasured on the second major surface, the second area being differentthan the first area.

Additional features and advantages will be set forth in the detaileddescription which follows, and in part will be readily apparent to thoseskilled in the art from that description or recognized by practicing theembodiments as described herein, including the detailed descriptionwhich follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description are merely exemplary, and areintended to provide an overview or framework to understanding the natureand character of the claims. The accompanying drawings are included toprovide a further understanding, and are incorporated in and constitutea part of this specification. The drawings illustrate one or moreembodiment(s), and together with the description serve to explainprinciples and operation of the various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustration of a vehicle interior withvehicle interior systems according to one or more embodiments;

FIG. 2 is a side view illustration of a curved display including a glasssubstrate and a display module, according to one or more embodiments;

FIG. 3 is a side view illustration of the glass substrate used in thecurved display of FIG. 2 ;

FIG. 4 is a front perspective view illustration of the glass substrateof FIG. 3 ;

FIG. 5 is a detailed view illustration of an embodiment of the displaymodule of FIG. 2 ;

FIG. 6 is a detailed view illustration of an alternative embodiment of adisplay module;

FIG. 7 is a detailed view illustration of the curved display of FIG. 2 ;

FIG. 8 is a process flow diagram of a method for forming the curveddisplay according to one or more embodiments; and

FIG. 9 is an illustration of the method described in FIG. 8 .

FIG. 10 is a flow diagram of a process for forming a curved display,according to another exemplary embodiment.

FIG. 11 is a flow diagram of a process for forming a curved display,according to another exemplary embodiment.

FIG. 12 is a detailed view of the process of FIG. 11 , according toanother exemplary embodiment.

FIG. 13 is a flow diagram of a process for forming a curved display,according to another exemplary embodiment.

FIG. 14 is a perspective view of a curved display, according to anexemplary embodiment.

FIG. 15 is a side view of the curved display of FIG. 14 , according toan exemplary embodiment.

FIGS. 16A-16I are side views of a kit according to one or moreembodiments.

FIGS. 17A-17I are side views of a kit according to one or moreembodiments.

FIGS. 18A and 18B are side views of a kit according to one or moreembodiments.

FIGS. 19A-19E are side view schematics illustrating one or moreembodiments of a method for forming a curved display.

FIGS. 20A and 20B are side view schematics illustrating a curved coverglass and corresponding adhesive stress profile with and without astress-reduction restraint according to one or more embodiments.

FIGS. 21A and 21B are side view schematics illustrating a curved coverglass and corresponding adhesive stress profile with and without astress-reduction design modification to the cover glass according to oneor more embodiments.

FIGS. 22A and 22B are side view schematics illustrating a curved coverglass with a hot-formed portion according to one or more embodiments.

DETAILED DESCRIPTION

Reference will now be made in detail to various embodiments, examples ofwhich are illustrated in the accompanying drawings. In general, avehicle interior system may include a variety of different curvedsurfaces that are designed to be transparent, such as curved displaysurfaces, and the present disclosure provides articles and methods forforming these curved surfaces from a glass material. Forming curvedvehicle surfaces from a glass material may provide a number ofadvantages compared to the typical curved plastic panels that areconventionally found in vehicle interiors. For example, glass istypically considered to provide enhanced functionality and userexperience for many curved cover material applications, such as displayapplications and touch screen applications, compared to plastic covermaterials.

While glass provides these benefits, curved glass articles are typicallyformed using hot forming processes. As discussed herein, a variety ofcurved glass articles and processes for making the same are providedthat avoid the deficiencies of the typical glass hot-forming process.For example, hot-forming processes are energy intensive and increase thecost of forming a curved glass component, relative to the cold-bendingprocess discussed herein. In addition, hot-forming processes typicallymake application of glass coating layers, such as anti-reflectivecoatings, significantly more difficult. For example, many coatingmaterials cannot be applied to a flat piece of glass material prior tothe hot-forming process because the coating material typically will notsurvive the high temperatures of the hot-forming process. Further,application of a coating material to surfaces of a curved glasssubstrate after hot-bending is substantially more difficult thanapplication to a flat glass substrate. In addition, Applicant believesthat by avoiding the additional high temperature heating steps neededfor thermal forming, the glass articles produced via the cold-formingprocesses and systems discussed herein have improved optical propertiesand/or improved surface properties than similarly shaped glass articlesmade via thermal-shaping processes.

In addition to these advantages relative to plastic cover sheets andhot-formed glass cover sheets, Applicant has found that the systems andprocesses discussed herein specifically provide for cold-bending ofthin, strengthened glass sheets in an economical and efficient process.As one example, Applicant has found that using air pressure (e.g., avacuum or overpressure) to bend the glass sheet provides a fast andaccurate way to conform the glass sheet to a curved device frame.Further, in some specific embodiments, the systems and processesdiscussed herein provide for bending and curing of bonding adhesivewithin common equipment and/or common processing steps. In addition, theprocesses and systems discussed herein may also allow for attachment ofthe display components to the glass cover sheet during bending utilizingcommon equipment and/or common processing steps.

A first aspect of the instant application pertains to a vehicle interiorsystem. The various embodiments of the vehicle interior system may beincorporated into vehicles such as trains, automobiles (e.g., cars,trucks, buses and the like), seacraft (boats, ships, submarines, and thelike), and aircraft (e.g., drones, airplanes, jets, helicopters and thelike).

FIG. 1 illustrates an exemplary vehicle interior 10 that includes threedifferent embodiments of a vehicle interior system 100, 200, 300.Vehicle interior system 100 includes a center console base 110 with acurved surface 120 including a curved display 130. Vehicle interiorsystem 200 includes a dashboard base 210 with a curved surface 220including a curved display 230. The dashboard base 210 typicallyincludes an instrument panel 215 which may also include a curveddisplay. Vehicle interior system 300 includes a dashboard steering wheelbase 310 with a curved surface 320 and a curved display 330. In one ormore embodiments, the vehicle interior system may include a base that isan arm rest, a pillar, a seat back, a floor board, a headrest, a doorpanel, or any portion of the interior of a vehicle that includes acurved surface.

The embodiments of the curved display described herein can be usedinterchangeably in each of vehicle interior systems 100, 200 and 300.Further, the curved glass articles discussed herein may be used ascurved cover glasses for any of the curved display embodiments discussedherein, including for use in vehicle interior systems 100, 200 and/or300.

As shown in FIG. 2 , in one or more embodiments the curved display 130includes cold-formed curved glass article or substrate 140 having afirst radius of curvature and a display module 150 attached to the glasssubstrate, wherein at least a portion of the display module 150 has asecond radius of curvature that approximates or matches the first radiusof curvature, to provide a curved display with a curved glass substrateas a cover glass.

Referring to FIGS. 3 and 4 , the glass substrate 140 includes a firstmajor surface 142 and a second major surface 144 opposite the firstmajor surface. The cold-formed glass substrate exhibits the first radiusof curvature as measured on the second major surface 144.

As used herein, the terms “cold-bent,” “cold-bending,” “cold-formed” or“cold-forming” refers to curving the glass substrate at a cold-formtemperature which is less than the softening point of the glass (asdescribed herein). A feature of a cold-formed glass substrate isasymmetric surface compressive between the first major surface 142 andthe second major surface 144. A minor surface 146 connects the firstmajor surface 142 and the second major surface 144. In one or moreembodiments, prior to the cold-forming process or being cold-formed, therespective compressive stresses in the first major surface 142 and thesecond major surface 144 of the glass substrate are substantially equal.In one or more embodiments in which the glass substrate isunstrengthened, the first major surface 142 and the second major surface144 exhibit no appreciable compressive stress, prior to cold-forming. Inone or more embodiments in which the glass substrate is strengthened (asdescribed herein), the first major surface 142 and the second majorsurface 144 exhibit substantially equal compressive stress with respectto one another, prior to cold-forming. In one or more embodiments, aftercold-forming (shown, for example, in FIGS. 2 and 7 , the compressivestress on the surface having a concave shape after bending (e.g., secondmajor surface 144 in FIGS. 2 and 7 ) increases. In other words, thecompressive stress on the concave surface (e.g., second major surface144) is greater after cold-forming than before cold-forming. Withoutbeing bound by theory, the cold-forming process increases thecompressive stress of the glass substrate being shaped to compensate fortensile stresses imparted during bending and/or forming operations. Inone or more embodiments, the cold-forming process causes the concavesurface (second major surface 144) to experience compressive stresses,while the surface forming a convex shape (i.e., the first major surface142 in FIGS. 2 and 7 ) after cold-forming experiences tensile stresses.The tensile stress experienced by the convex (i.e., the first majorsurface 142) following cold-forming results in a net decrease in surfacecompressive stress, such that the compressive stress in convex surface(i.e., the first major surface 142) of a strengthened glass sheetfollowing cold-forming is less than the compressive stress on the samesurface (i.e., first major surface 142) when the glass sheet is flat.

When a strengthened glass substrate is utilized, the first major surfaceand the second major surface (142, 144) are already under compressivestress, and thus the first major surface can experience greater tensilestress during bending without risking fracture. This allows for thestrengthened glass substrate to conform to more tightly curved surfaces.

In one or more embodiments, the thickness of the glass substrate istailored to allow the glass substrate to be more flexible to achieve thedesired radius of curvature. Moreover, a thinner glass substrate 140 maydeform more readily, which could potentially compensate for shapemismatches and gaps that may be created by the shape of the displaymodule 150. In one or more embodiments, a thin and strengthened glasssubstrate 140 exhibits greater flexibility especially duringcold-forming. The greater flexibility of the glass substrates discussedherein may both allow for sufficient degrees of bending to be createdvia the air pressure-based bending processes as discussed herein andalso for consistent bend formation without heating. In one or moreembodiments, the glass substrate 140 and at least a portion of thedisplay module 150 have substantially similar radii of curvature toprovide a substantially uniform distance between the first major surface142 and the display module 150 (which may be filled with an adhesive).

In one or more embodiments, the cold-formed glass substrate and thecurved display may have a compound curve including a major radius and across curvature. A complexly curved cold-formed glass substrate and thedisplay according to one or more embodiments may have a distinct radiusof curvature in two independent directions. According to one or moreembodiments, the complexly curved cold-formed glass substrate and thecurved display may thus be characterized as having “cross curvature,”where the cold-formed glass substrate and the curved display are curvedalong an axis (i.e., a first axis) that is parallel to a given dimensionand also curved along an axis (i.e., a second axis) that isperpendicular to the same dimension. The curvature of the cold-formedglass substrate and the curved display can be even more complex when asignificant minimum radius is combined with a significant crosscurvature, and/or depth of bend.

In the embodiment shown, the glass substrate has a thickness (t) that issubstantially constant and is defined as a distance between the firstmajor surface 142 and the second major surface 144. The thickness (t) asused herein refers to the maximum thickness of the glass substrate. Inthe embodiment shown in FIGS. 3-4 , the glass substrate includes a width(W) defined as a first maximum dimension of one of the first or secondmajor surfaces orthogonal to the thickness (t), and a length (L) definedas a second maximum dimension of one of the first or second surfacesorthogonal to both the thickness and the width. In other embodiments,the dimensions discussed herein may be average dimensions.

In one or more embodiments, the glass substrate has a thickness (t) thatis about 1.5 mm or less. For example, the thickness may be in a rangefrom about 0.1 mm to about 1.5 mm, from about 0.15 mm to about 1.5 mm,from about 0.2 mm to about 1.5 mm, from about 0.25 mm to about 1.5 mm,from about 0.3 mm to about 1.5 mm, from about 0.35 mm to about 1.5 mm,from about 0.4 mm to about 1.5 mm, from about 0.45 mm to about 1.5 mm,from about 0.5 mm to about 1.5 mm, from about 0.55 mm to about 1.5 mm,from about 0.6 mm to about 1.5 mm, from about 0.65 mm to about 1.5 mm,from about 0.7 mm to about 1.5 mm, from about 0.1 mm to about 1.4 mm,from about 0.1 mm to about 1.3 mm, from about 0.1 mm to about 1.2 mm,from about 0.1 mm to about 1.1 mm, from about 0.1 mm to about 1.05 mm,from about 0.1 mm to about 1 mm, from about 0.1 mm to about 0.95 mm,from about 0.1 mm to about 0.9 mm, from about 0.1 mm to about 0.85 mm,from about 0.1 mm to about 0.8 mm, from about 0.1 mm to about 0.75 mm,from about 0.1 mm to about 0.7 mm, from about 0.1 mm to about 0.65 mm,from about 0.1 mm to about 0.6 mm, from about 0.1 mm to about 0.55 mm,from about 0.1 mm to about 0.5 mm, from about 0.1 mm to about 0.4 mm, orfrom about 0.3 mm to about 0.7 mm.

In one or more embodiments, the glass substrate has a width (W) in arange from about 5 cm to about 250 cm, from about 10 cm to about 250 cm,from about 15 cm to about 250 cm, from about 20 cm to about 250 cm, fromabout 25 cm to about 250 cm, from about 30 cm to about 250 cm, fromabout 35 cm to about 250 cm, from about 40 cm to about 250 cm, fromabout 45 cm to about 250 cm, from about 50 cm to about 250 cm, fromabout 55 cm to about 250 cm, from about 60 cm to about 250 cm, fromabout 65 cm to about 250 cm, from about 70 cm to about 250 cm, fromabout 75 cm to about 250 cm, from about 80 cm to about 250 cm, fromabout 85 cm to about 250 cm, from about 90 cm to about 250 cm, fromabout 95 cm to about 250 cm, from about 100 cm to about 250 cm, fromabout 110 cm to about 250 cm, from about 120 cm to about 250 cm, fromabout 130 cm to about 250 cm, from about 140 cm to about 250 cm, fromabout 150 cm to about 250 cm, from about 5 cm to about 240 cm, fromabout 5 cm to about 230 cm, from about 5 cm to about 220 cm, from about5 cm to about 210 cm, from about 5 cm to about 200 cm, from about 5 cmto about 190 cm, from about 5 cm to about 180 cm, from about 5 cm toabout 170 cm, from about 5 cm to about 160 cm, from about 5 cm to about150 cm, from about 5 cm to about 140 cm, from about 5 cm to about 130cm, from about 5 cm to about 120 cm, from about 5 cm to about 110 cm,from about 5 cm to about 110 cm, from about 5 cm to about 100 cm, fromabout 5 cm to about 90 cm, from about 5 cm to about 80 cm, or from about5 cm to about 75 cm.

In one or more embodiments, the glass substrate has a length (L) in arange from about 5 cm to about 250 cm, from about 10 cm to about 250 cm,from about 15 cm to about 250 cm, from about 20 cm to about 250 cm, fromabout 25 cm to about 250 cm, from about 30 cm to about 250 cm, fromabout 35 cm to about 250 cm, from about 40 cm to about 250 cm, fromabout 45 cm to about 250 cm, from about 50 cm to about 250 cm, fromabout 55 cm to about 250 cm, from about 60 cm to about 250 cm, fromabout 65 cm to about 250 cm, from about 70 cm to about 250 cm, fromabout 75 cm to about 250 cm, from about 80 cm to about 250 cm, fromabout 85 cm to about 250 cm, from about 90 cm to about 250 cm, fromabout 95 cm to about 250 cm, from about 100 cm to about 250 cm, fromabout 110 cm to about 250 cm, from about 120 cm to about 250 cm, fromabout 130 cm to about 250 cm, from about 140 cm to about 250 cm, fromabout 150 cm to about 250 cm, from about 5 cm to about 240 cm, fromabout 5 cm to about 230 cm, from about 5 cm to about 220 cm, from about5 cm to about 210 cm, from about 5 cm to about 200 cm, from about 5 cmto about 190 cm, from about 5 cm to about 180 cm, from about 5 cm toabout 170 cm, from about 5 cm to about 160 cm, from about 5 cm to about150 cm, from about 5 cm to about 140 cm, from about 5 cm to about 130cm, from about 5 cm to about 120 cm, from about 5 cm to about 110 cm,from about 5 cm to about 110 cm, from about 5 cm to about 100 cm, fromabout 5 cm to about 90 cm, from about 5 cm to about 80 cm, or from about5 cm to about 75 cm.

In one or more embodiments, the glass substrate may be strengthened. Inone or more embodiments, the glass substrate may be strengthened toinclude compressive stress that extends from a surface to a depth ofcompression (DOC). The compressive stress regions are balanced by acentral portion exhibiting a tensile stress. At the DOC, the stresscrosses from a positive (compressive) stress to a negative (tensile)stress.

In one or more embodiments, the glass substrate may be strengthenedmechanically by utilizing a mismatch of the coefficient of thermalexpansion between portions of the article to create a compressive stressregion and a central region exhibiting a tensile stress. In someembodiments, the glass substrate may be strengthened thermally byheating the glass to a temperature above the glass transition point andthen rapidly quenching.

In one or more embodiments, the glass substrate may be chemicallystrengthening by ion exchange. In the ion exchange process, ions at ornear the surface of the glass substrate are replaced by—or exchangedwith—larger ions having the same valence or oxidation state. In thoseembodiments in which the glass substrate comprises an alkalialuminosilicate glass, ions in the surface layer of the article and thelarger ions are monovalent alkali metal cations, such as Li⁺, Na⁺, K⁺,Rb⁺, and Cs⁺. Alternatively, monovalent cations in the surface layer maybe replaced with monovalent cations other than alkali metal cations,such as Ag⁺ or the like. In such embodiments, the monovalent ions (orcations) exchanged into the glass substrate generate a stress.

Ion exchange processes are typically carried out by immersing a glasssubstrate in a molten salt bath (or two or more molten salt baths)containing the larger ions to be exchanged with the smaller ions in theglass substrate. It should be noted that aqueous salt baths may also beutilized. In addition, the composition of the bath(s) may include morethan one type of larger ion (e.g., Na+ and K+) or a single larger ion.It will be appreciated by those skilled in the art that parameters forthe ion exchange process, including, but not limited to, bathcomposition and temperature, immersion time, the number of immersions ofthe glass substrate in a salt bath (or baths), use of multiple saltbaths, additional steps such as annealing, washing, and the like, aregenerally determined by the composition of the glass substrate(including the structure of the article and any crystalline phasespresent) and the desired DOC and CS of the glass substrate that resultsfrom strengthening. Exemplary molten bath composition may includenitrates, sulfates, and chlorides of the larger alkali metal ion.Typical nitrates include KNO₃, NaNO₃, LiNO₃, NaSO₄ and combinationsthereof. The temperature of the molten salt bath typically is in a rangefrom about 380° C. up to about 450° C., while immersion times range fromabout 15 minutes up to about 100 hours depending on glass substratethickness, bath temperature and glass (or monovalent ion) diffusivity.However, temperatures and immersion times different from those describedabove may also be used.

In one or more embodiments, the glass substrates may be immersed in amolten salt bath of 100% NaNO₃, 100% KNO₃, or a combination of NaNO₃ andKNO₃ having a temperature from about 370° C. to about 480° C. In someembodiments, the glass substrate may be immersed in a molten mixed saltbath including from about 5% to about 90% KNO₃ and from about 10% toabout 95% NaNO₃. In one or more embodiments, the glass substrate may beimmersed in a second bath, after immersion in a first bath. The firstand second baths may have different compositions and/or temperaturesfrom one another. The immersion times in the first and second baths mayvary. For example, immersion in the first bath may be longer than theimmersion in the second bath.

In one or more embodiments, the glass substrate may be immersed in amolten, mixed salt bath including NaNO₃ and KNO₃ (e.g., 49%/51%,50%/50%, 51%/49%) having a temperature less than about 420° C. (e.g.,about 400° C. or about 380° C.). for less than about 5 hours, or evenabout 4 hours or less.

Ion exchange conditions can be tailored to provide a “spike” or toincrease the slope of the stress profile at or near the surface of theresulting glass substrate. The spike may result in a greater surface CSvalue. This spike can be achieved by single bath or multiple baths, withthe bath(s) having a single composition or mixed composition, due to theunique properties of the glass compositions used in the glass substratesdescribed herein.

In one or more embodiments, where more than one monovalent ion isexchanged into the glass substrate, the different monovalent ions mayexchange to different depths within the glass substrate (and generatedifferent magnitudes stresses within the glass substrate at differentdepths). The resulting relative depths of the stress-generating ions canbe determined and cause different characteristics of the stress profile.

CS is measured using those means known in the art, such as by surfacestress meter (FSM) using commercially available instruments such as theFSM-6000, manufactured by Orihara Industrial Co., Ltd. (Japan). Surfacestress measurements rely upon the accurate measurement of the stressoptical coefficient (SOC), which is related to the birefringence of theglass. SOC in turn is measured by those methods that are known in theart, such as fiber and four point bend methods, both of which aredescribed in ASTM standard C770-98 (2013), entitled “Standard TestMethod for Measurement of Glass Stress-Optical Coefficient,” thecontents of which are incorporated herein by reference in theirentirety, and a bulk cylinder method. As used herein CS may be the“maximum compressive stress” which is the highest compressive stressvalue measured within the compressive stress layer. In some embodiments,the maximum compressive stress is located at the surface of the glasssubstrate. In other embodiments, the maximum compressive stress mayoccur at a depth below the surface, giving the compressive profile theappearance of a “buried peak.”

DOC may be measured by FSM or by a scattered light polariscope (SCALP)(such as the SCALP-04 scattered light polariscope available fromGlasstress Ltd., located in Tallinn Estonia), depending on thestrengthening method and conditions. When the glass substrate ischemically strengthened by an ion exchange treatment, FSM or SCALP maybe used depending on which ion is exchanged into the glass substrate.Where the stress in the glass substrate is generated by exchangingpotassium ions into the glass substrate, FSM is used to measure DOC.Where the stress is generated by exchanging sodium ions into the glasssubstrate, SCALP is used to measure DOC. Where the stress in the glasssubstrate is generated by exchanging both potassium and sodium ions intothe glass, the DOC is measured by SCALP, since it is believed theexchange depth of sodium indicates the DOC and the exchange depth ofpotassium ions indicates a change in the magnitude of the compressivestress (but not the change in stress from compressive to tensile); theexchange depth of potassium ions in such glass substrates is measured byFSM. Central tension or CT is the maximum tensile stress and is measuredby SCALP.

In one or more embodiments, the glass substrate maybe strengthened toexhibit a DOC that is described a fraction of the thickness t of theglass substrate (as described herein). For example, in one or moreembodiments, the DOC may be equal to or greater than about 0.05 t, equalto or greater than about 0.1 t, equal to or greater than about 0.11 t,equal to or greater than about 0.12 t, equal to or greater than about0.13 t, equal to or greater than about 0.14 t, equal to or greater thanabout 0.15 t, equal to or greater than about 0.16 t, equal to or greaterthan about 0.17 t, equal to or greater than about 0.18 t, equal to orgreater than about 0.19 t, equal to or greater than about 0.2 t, equalto or greater than about 0.21t. In some embodiments, The DOC may be in arange from about 0.08 t to about 0.25 t, from about 0.09t to about 0.25t, from about 0.18 t to about 0.25 t, from about 0.11 t to about 0.25 t,from about 0.12 t to about 0.25 t, from about 0.13 t to about 0.25 t,from about 0.14 t to about 0.25 t, from about 0.15 t to about 0.25 t,from about 0.08 t to about 0.24 t, from about 0.08 t to about 0.23 t,from about 0.08 t to about 0.22 t, from about 0.08 t to about 0.21 t,from about 0.08 t to about 0.2 t, from about 0.08 t to about 0.19 t,from about 0.08 t to about 0.18 t, from about 0.08 t to about 0.17 t,from about 0.08 t to about 0.16 t, or from about 0.08 t to about 0.15t.In some instances, the DOC may be about 20 μm or less. In one or moreembodiments, the DOC may be about 40 μm or greater (e.g., from about 40μm to about 300 μm, from about 50 μm to about 300 μm, from about 60 μmto about 300 μm, from about 70 μm to about 300 μm, from about 80 μm toabout 300 μm, from about 90 μm to about 300 μm, from about 100 μm toabout 300 μm, from about 110 μm to about 300 μm, from about 120 μm toabout 300 μm, from about 140 μm to about 300 μm, from about 150 μm toabout 300 μm, from about 40 μm to about 290 μm, from about 40 μm toabout 280 μm, from about 40 μm to about 260 μm, from about 40 μm toabout 250 μm, from about 40 μm to about 240 μm, from about 40 μm toabout 230 μm, from about 40 μm to about 220 μm, from about 40 μm toabout 210 μm, from about 40 μm to about 200 μm, from about 40 μm toabout 180 μm, from about 40 μm to about 160 μm, from about 40 μm toabout 150 μm, from about 40 μm to about 140 μm, from about 40 μm toabout 130 μm, from about 40 μm to about 120 μm, from about 40 μm toabout 110 μm, or from about 40 μm to about 100 μm.

In one or more embodiments, the strengthened glass substrate may have aCS (which may be found at the surface or a depth within the glasssubstrate) of about 200 MPa or greater, 300 MPa or greater, 400 MPa orgreater, about 500 MPa or greater, about 600 MPa or greater, about 700MPa or greater, about 800 MPa or greater, about 900 MPa or greater,about 930 MPa or greater, about 1000 MPa or greater, or about 1050 MPaor greater.

In one or more embodiments, the strengthened glass substrate may have amaximum tensile stress or central tension (CT) of about 20 MPa orgreater, about 30 MPa or greater, about 40 MPa or greater, about 45 MPaor greater, about 50 MPa or greater, about 60 MPa or greater, about 70MPa or greater, about 75 MPa or greater, about 80 MPa or greater, orabout 85 MPa or greater. In some embodiments, the maximum tensile stressor central tension (CT) may be in a range from about 40 MPa to about 100MPa.

Suitable glass compositions for use in the glass substrate include sodalime glass, aluminosilicate glass, borosilicate glass,boroaluminosilicate glass, alkali-containing aluminosilicate glass,alkali-containing borosilicate glass, and alkali-containingboroaluminosilicate glass.

Unless otherwise specified, the glass compositions disclosed herein aredescribed in mole percent (mol %) as analyzed on an oxide basis.

In one or more embodiments, the glass composition may include SiO₂ in anamount in a range from about 66 mol % to about 80 mol %, from about 67mol % to about 80 mol %, from about 68 mol % to about 80 mol %, fromabout 69 mol % to about 80 mol %, from about 70 mol % to about 80 mol %,from about 72 mol % to about 80 mol %, from about 65 mol % to about 78mol %, from about 65 mol % to about 76 mol %, from about 65 mol % toabout 75 mol %, from about 65 mol % to about 74 mol %, from about 65 mol% to about 72 mol %, or from about 65 mol % to about 70 mol %, and allranges and sub-ranges therebetween.

In one or more embodiments, the glass composition includes Al₂O₃ in anamount greater than about 4 mol %, or greater than about 5 mol %. In oneor more embodiments, the glass composition includes Al₂O₃ in a rangefrom greater than about 7 mol % to about 15 mol %, from greater thanabout 7 mol % to about 14 mol %, from about 7 mol % to about 13 mol %,from about 4 mol % to about 12 mol %, from about 7 mol % to about 11 mol%, from about 8 mol % to about 15 mol %, from 9 mol % to about 15 mol %,from about 9 mol % to about 15 mol %, from about 10 mol % to about 15mol %, from about 11 mol % to about 15 mol %, or from about 12 mol % toabout 15 mol %, and all ranges and sub-ranges therebetween. In one ormore embodiments, the upper limit of Al₂O₃ may be about 14 mol %, 14.2mol %, 14.4 mol %, 14.6 mol %, or 14.8 mol %.

In one or more embodiments, the glass article is described as analuminosilicate glass article or including an aluminosilicate glasscomposition. In such embodiments, the glass composition or articleformed therefrom includes SiO₂ and Al₂O₃ and is not a soda lime silicateglass. In this regard, the glass composition or article formed therefromincludes Al₂O₃ in an amount of about 2 mol % or greater, 2.25 mol % orgreater, 2.5 mol % or greater, about 2.75 mol % or greater, about 3 mol% or greater.

In one or more embodiments, the glass composition comprises B₂O₃ (e.g.,about 0.01 mol % or greater). In one or more embodiments, the glasscomposition comprises B₂O₃ in an amount in a range from about 0 mol % toabout 5 mol %, from about 0 mol % to about 4 mol %, from about 0 mol %to about 3 mol %, from about 0 mol % to about 2 mol %, from about 0 mol% to about 1 mol %, from about 0 mol % to about 0.5 mol %, from about0.1 mol % to about 5 mol %, from about 0.1 mol % to about 4 mol %, fromabout 0.1 mol % to about 3 mol %, from about 0.1 mol % to about 2 mol %,from about 0.1 mol % to about 1 mol %, from about 0.1 mol % to about 0.5mol %, and all ranges and sub-ranges therebetween. In one or moreembodiments, the glass composition is substantially free of B₂O₃.

As used herein, the phrase “substantially free” with respect to thecomponents of the composition means that the component is not activelyor intentionally added to the composition during initial batching, butmay be present as an impurity in an amount less than about 0.001 mol %.

In one or more embodiments, the glass composition optionally comprisesP₂O₅ (e.g., about 0.01 mol % or greater). In one or more embodiments,the glass composition comprises a non-zero amount of P₂O₅ up to andincluding 2 mol %, 1.5 mol %, 1 mol %, or 0.5 mol %. In one or moreembodiments, the glass composition is substantially free of P₂O₅.

In one or more embodiments, the glass composition may include a totalamount of R₂O (which is the total amount of alkali metal oxide such asLi₂O, Na₂O, K₂O, Rb₂O, and Cs₂O) that is greater than or equal to about8 mol %, greater than or equal to about 10 mol %, or greater than orequal to about 12 mol %. In some embodiments, the glass compositionincludes a total amount of R₂O in a range from about 8 mol % to about 20mol %, from about 8 mol % to about 18 mol %, from about 8 mol % to about16 mol %, from about 8 mol % to about 14 mol %, from about 8 mol % toabout 12 mol %, from about 9 mol % to about 20 mol %, from about 10 mol% to about 20 mol %, from about 11 mol % to about 20 mol %, from about12 mol % to about 20 mol %, from about 13 mol % to about 20 mol %, fromabout 10 mol % to about 14 mol %, or from 11 mol % to about 13 mol %,and all ranges and sub-ranges therebetween. In one or more embodiments,the glass composition may be substantially free of Rb₂O, Cs₂O or bothRb₂O and Cs₂O. In one or more embodiments, the R₂O may include the totalamount of Li₂O, Na₂O and K₂O only. In one or more embodiments, the glasscomposition may comprise at least one alkali metal oxide selected fromLi₂O, Na₂O and K₂O, wherein the alkali metal oxide is present in anamount greater than about 8 mol % or greater.

In one or more embodiments, the glass composition comprises Na₂O in anamount greater than or equal to about 8 mol %, greater than or equal toabout 10 mol %, or greater than or equal to about 12 mol %. In one ormore embodiments, the composition includes Na₂O in a range from aboutfrom about 8 mol % to about 20 mol %, from about 8 mol % to about 18 mol%, from about 8 mol % to about 16 mol %, from about 8 mol % to about 14mol %, from about 8 mol % to about 12 mol %, from about 9 mol % to about20 mol %, from about 10 mol % to about 20 mol %, from about 11 mol % toabout 20 mol %, from about 12 mol % to about 20 mol %, from about 13 mol% to about 20 mol %, from about 10 mol % to about 14 mol %, or from 11mol % to about 16 mol %, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition includes less thanabout 4 mol % K₂O, less than about 3 mol % K₂O, or less than about 1 mol% K₂O. In some instances, the glass composition may include K₂O in anamount in a range from about 0 mol % to about 4 mol %, from about 0 mol% to about 3.5 mol %, from about 0 mol % to about 3 mol %, from about 0mol % to about 2.5 mol %, from about 0 mol % to about 2 mol %, fromabout 0 mol % to about 1.5 mol %, from about 0 mol % to about 1 mol %,from about 0 mol % to about 0.5 mol %, from about 0 mol % to about 0.2mol %, from about 0 mol % to about 0.1 mol %, from about 0.5 mol % toabout 4 mol %, from about 0.5 mol % to about 3.5 mol %, from about 0.5mol % to about 3 mol %, from about 0.5 mol % to about 2.5 mol %, fromabout 0.5 mol % to about 2 mol %, from about 0.5 mol % to about 1.5 mol%, or from about 0.5 mol % to about 1 mol %, and all ranges andsub-ranges therebetween. In one or more embodiments, the glasscomposition may be substantially free of K₂O.

In one or more embodiments, the glass composition is substantially freeof Li₂O.

In one or more embodiments, the amount of Na₂O in the composition may begreater than the amount of Li₂O. In some instances, the amount of Na₂Omay be greater than the combined amount of Li₂O and K₂O. In one or morealternative embodiments, the amount of Li₂O in the composition may begreater than the amount of Na₂O or the combined amount of Na₂O and K₂O.

In one or more embodiments, the glass composition may include a totalamount of RO (which is the total amount of alkaline earth metal oxidesuch as CaO, MgO, BaO, ZnO and SrO) in a range from about 0 mol % toabout 2 mol %. In some embodiments, the glass composition includes anon-zero amount of RO up to about 2 mol %. In one or more embodiments,the glass composition comprises RO in an amount from about 0 mol % toabout 1.8 mol %, from about 0 mol % to about 1.6 mol %, from about 0 mol% to about 1.5 mol %, from about 0 mol % to about 1.4 mol %, from about0 mol % to about 1.2 mol %, from about 0 mol % to about 1 mol %, fromabout 0 mol % to about 0.8 mol %, from about 0 mol % to about 0.5 mol %,and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition includes CaO in anamount less than about 1 mol %, less than about 0.8 mol %, or less thanabout 0.5 mol %. In one or more embodiments, the glass composition issubstantially free of CaO.

In some embodiments, the glass composition comprises MgO in an amountfrom about 0 mol % to about 7 mol %, from about 0 mol % to about 6 mol%, from about 0 mol % to about 5 mol %, from about 0 mol % to about 4mol %, from about 0.1 mol % to about 7 mol %, from about 0.1 mol % toabout 6 mol %, from about 0.1 mol % to about 5 mol %, from about 0.1 mol% to about 4 mol %, from about 1 mol % to about 7 mol %, from about 2mol % to about 6 mol %, or from about 3 mol % to about 6 mol %, and allranges and sub-ranges therebetween.

In one or more embodiments, the glass composition comprises ZrO₂ in anamount equal to or less than about 0.2 mol %, less than about 0.18 mol%, less than about 0.16 mol %, less than about 0.15 mol %, less thanabout 0.14 mol %, less than about 0.12 mol %. In one or moreembodiments, the glass composition comprises ZrO₂ in a range from about0.01 mol % to about 0.2 mol %, from about 0.01 mol % to about 0.18 mol%, from about 0.01 mol % to about 0.16 mol %, from about 0.01 mol % toabout 0.15 mol %, from about 0.01 mol % to about 0.14 mol %, from about0.01 mol % to about 0.12 mol %, or from about 0.01 mol % to about 0.10mol %, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition comprises SnO₂ in anamount equal to or less than about 0.2 mol %, less than about 0.18 mol%, less than about 0.16 mol %, less than about 0.15 mol %, less thanabout 0.14 mol %, less than about 0.12 mol %. In one or moreembodiments, the glass composition comprises SnO₂ in a range from about0.01 mol % to about 0.2 mol %, from about 0.01 mol % to about 0.18 mol%, from about 0.01 mol % to about 0.16 mol %, from about 0.01 mol % toabout 0.15 mol %, from about 0.01 mol % to about 0.14 mol %, from about0.01 mol % to about 0.12 mol %, or from about 0.01 mol % to about 0.10mol %, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition may include an oxidethat imparts a color or tint to the glass articles. In some embodiments,the glass composition includes an oxide that prevents discoloration ofthe glass article when the glass article is exposed to ultravioletradiation. Examples of such oxides include, without limitation oxidesof: Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Ce, W, and Mo.

In one or more embodiments, the glass composition includes Fe expressedas Fe₂O₃, wherein Fe is present in an amount up to (and including) about1 mol %. In some embodiments, the glass composition is substantiallyfree of Fe. In one or more embodiments, the glass composition comprisesFe₂O₃ in an amount equal to or less than about 0.2 mol %, less thanabout 0.18 mol %, less than about 0.16 mol %, less than about 0.15 mol%, less than about 0.14 mol %, less than about 0.12 mol %. In one ormore embodiments, the glass composition comprises Fe₂O₃ in a range fromabout 0.01 mol % to about 0.2 mol %, from about 0.01 mol % to about 0.18mol %, from about 0.01 mol % to about 0.16 mol %, from about 0.01 mol %to about 0.15 mol %, from about 0.01 mol % to about 0.14 mol %, fromabout 0.01 mol % to about 0.12 mol %, or from about 0.01 mol % to about0.10 mol %, and all ranges and sub-ranges therebetween.

Where the glass composition includes TiO₂, TiO₂ may be present in anamount of about 5 mol % or less, about 2.5 mol % or less, about 2 mol %or less or about 1 mol % or less. In one or more embodiments, the glasscomposition may be substantially free of TiO₂.

An exemplary glass composition includes SiO₂ in an amount in a rangefrom about 65 mol % to about 75 mol %, Al₂O₃ in an amount in a rangefrom about 8 mol % to about 14 mol %, Na₂O in an amount in a range fromabout 12 mol % to about 17 mol %, K₂O in an amount in a range of about 0mol % to about 0.2 mol %, and MgO in an amount in a range from about 1.5mol % to about 6 mol %. Optionally, SnO₂ may be included in the amountsotherwise disclosed herein.

In one or more embodiments, the cold-formed glass substrate 140 has acurvature (first radius of curvature) that matches the curvature (secondradius of curvature) of at least a portion of the display module 150. Inone or more embodiments, at least a portion of the display module 150 iscurved to approach or match the curvature of the cold-formed glasssubstrate 140. In one or more embodiments, the display module 150includes a second glass substrate, a backlight unit and othercomponents, any of which may be flexible or may permanently exhibit acurvature. In some embodiments, the entire display module is curved to asecond radius of curvature. In one or more embodiments, the glasssubstrate 140 is cold-formed to a curvature that approaches or matchesthe curvature of at least a portion of the display module 150. In one ormore embodiments, at least a portion of the display module 150 iscold-formed to a curvature that approaches or matches the curvature ofthe cold-formed glass substrate 140.

As used herein, when the first radius of curvature of the glasssubstrate varies across its area, the radius of curvature referred toherein is the minimum first radius of curvature of the glass substrate.Similarly, when the second radius of curvature of the display modulevaries across its area, the second radius of curvature referred toherein is the minimum radius of curvature of the display module.

In one or more embodiments, the glass substrate 140 has a first radiusof curvature of about 60 mm or greater. For example, the first radius ofcurvature may be in a range from about 60 mm to about 1500 mm, fromabout 70 mm to about 1500 mm, from about 80 mm to about 1500 mm, fromabout 90 mm to about 1500 mm, from about 100 mm to about 1500 mm, fromabout 120 mm to about 1500 mm, from about 140 mm to about 1500 mm, fromabout 150 mm to about 1500 mm, from about 160 mm to about 1500 mm, fromabout 180 mm to about 1500 mm, from about 200 mm to about 1500 mm, fromabout 220 mm to about 1500 mm, from about 240 mm to about 1500 mm, fromabout 250 mm to about 1500 mm, from about 260 mm to about 1500 mm, fromabout 270 mm to about 1500 mm, from about 280 mm to about 1500 mm, fromabout 290 mm to about 1500 mm, from about 300 mm to about 1500 mm, fromabout 350 mm to about 1500 mm, from about 400 mm to about 1500 mm, fromabout 450 mm to about 1500 mm, from about 500 mm to about 1500 mm, fromabout 550 mm to about 1500 mm, from about 600 mm to about 1500 mm, fromabout 650 mm to about 1500 mm, from about 700 mm to about 1500 mm, fromabout 750 mm to about 1500 mm, from about 800 mm to about 1500 mm, fromabout 900 mm to about 1500 mm, from about 9500 mm to about 1500 mm, fromabout 1000 mm to about 1500 mm, from about 1250 mm to about 1500 mm,from about 60 mm to about 1400 mm, from about 60 mm to about 1300 mm,from about 60 mm to about 1200 mm, from about 60 mm to about 1100 mm,from about 60 mm to about 1000 mm, from about 60 mm to about 950 mm,from about 60 mm to about 900 mm, from about 60 mm to about 850 mm, fromabout 60 mm to about 800 mm, from about 60 mm to about 750 mm, fromabout 60 mm to about 700 mm, from about 60 mm to about 650 mm, fromabout 60 mm to about 600 mm, from about 60 mm to about 550 mm, fromabout 60 mm to about 500 mm, from about 60 mm to about 450 mm, fromabout 60 mm to about 400 mm, from about 60 mm to about 350 mm, fromabout 60 mm to about 300 mm, or from about 60 mm to about 250 mm.

In one or more embodiments, the display module 150 has a second radiusof curvature of about 60 mm or greater. For example, the first radius ofcurvature may be in a range from about 60 mm to about 1500 mm, fromabout 70 mm to about 1500 mm, from about 80 mm to about 1500 mm, fromabout 90 mm to about 1500 mm, from about 100 mm to about 1500 mm, fromabout 120 mm to about 1500 mm, from about 140 mm to about 1500 mm, fromabout 150 mm to about 1500 mm, from about 160 mm to about 1500 mm, fromabout 180 mm to about 1500 mm, from about 200 mm to about 1500 mm, fromabout 220 mm to about 1500 mm, from about 240 mm to about 1500 mm, fromabout 250 mm to about 1500 mm, from about 260 mm to about 1500 mm, fromabout 270 mm to about 1500 mm, from about 280 mm to about 1500 mm, fromabout 290 mm to about 1500 mm, from about 300 mm to about 1500 mm, fromabout 350 mm to about 1500 mm, from about 400 mm to about 1500 mm, fromabout 450 mm to about 1500 mm, from about 500 mm to about 1500 mm, fromabout 550 mm to about 1500 mm, from about 600 mm to about 1500 mm, fromabout 650 mm to about 1500 mm, from about 700 mm to about 1500 mm, fromabout 750 mm to about 1500 mm, from about 800 mm to about 1500 mm, fromabout 900 mm to about 1500 mm, from about 9500 mm to about 1500 mm, fromabout 1000 mm to about 1500 mm, from about 1250 mm to about 1500 mm,from about 60 mm to about 1400 mm, from about 60 mm to about 1300 mm,from about 60 mm to about 1200 mm, from about 60 mm to about 1100 mm,from about 60 mm to about 1000 mm, from about 60 mm to about 950 mm,from about 60 mm to about 900 mm, from about 60 mm to about 850 mm, fromabout 60 mm to about 800 mm, from about 60 mm to about 750 mm, fromabout 60 mm to about 700 mm, from about 60 mm to about 650 mm, fromabout 60 mm to about 600 mm, from about 60 mm to about 550 mm, fromabout 60 mm to about 500 mm, from about 60 mm to about 450 mm, fromabout 60 mm to about 400 mm, from about 60 mm to about 350 mm, fromabout 60 mm to about 300 mm, or from about 60 mm to about 250 mm.

In one or more embodiments, the glass substrate is cold-formed toexhibit a first radius curvature that is within 10% (e.g., about 10% orless, about 9% or less, about 8% or less, about 7% or less, about 6% orless, or about 5% or less) of the second radius of curvature of thedisplay module 150. For example, if the display module 150 exhibits aradius of curvature of 1000 mmm, the glass substrate is cold-formed tohave a radius of curvature in a range from about 900 mm to about 1100mm.

In one or more embodiments, the display module 150 as shown in FIG. 5and includes a second glass substrate 152 and a backlight unit 154. Asshown in FIG. 6 and FIG. 7 , the second glass substrate is disposedadjacent the first major surface 142 of the glass substrate.Accordingly, the second glass substrate 152 is disposed between thebacklight unit 154 and the first major surface 142. In the embodimentshown, the backlight unit 154 is optionally curved to exhibit the secondradius of curvature of the curved display 150. In one or moreembodiments, the backlight unit 154 may be flexible to curve to thesecond radius of curvature. In one or more embodiments, the second glasssubstrate 152 may be curved to the second radius of curvature. In one ormore specific embodiments, the second glass substrate may be cold-formedto exhibit the second radius of curvature. In such embodiments, thesecond radius of curvature is measured on the surface of the secondglass substrate 152 adjacent the glass substrate 140. In one or moreembodiments, the display module 150 (including any one or more of thebacklight unit, the second glass substrate, and the frame) arepermanently curved to the second radius of curvature of the curveddisplay 150. In one or more embodiments, the second glass substrate maybe cold-formed before or during lamination.

In one or more embodiments, the second glass substrate may have athickness greater than the thickness of the glass substrate. In one ormore embodiments, the thickness is greater than 1 mm, or about 1.5 mm orgreater. In one or more embodiments, the thickness of the second glasssubstrate may have a thickness that is substantially the same as theglass substrate. In one or more embodiments, the second glass substratehas a thickness in a range from about 0.1 mm to about 1.5 mm, from about0.15 mm to about 1.5 mm, from about 0.2 mm to about 1.5 mm, from about0.25 mm to about 1.5 mm, from about 0.3 mm to about 1.5 mm, from about0.35 mm to about 1.5 mm, from about 0.4 mm to about 1.5 mm, from about0.45 mm to about 1.5 mm, from about 0.5 mm to about 1.5 mm, from about0.55 mm to about 1.5 mm, from about 0.6 mm to about 1.5 mm, from about0.65 mm to about 1.5 mm, from about 0.7 mm to about 1.5 mm, from about0.1 mm to about 1.4 mm, from about 0.1 mm to about 1.3 mm, from about0.1 mm to about 1.2 mm, from about 0.1 mm to about 1.1 mm, from about0.1 mm to about 1.05 mm, from about 0.1 mm to about 1 mm, from about 0.1mm to about 0.95 mm, from about 0.1 mm to about 0.9 mm, from about 0.1mm to about 0.85 mm, from about 0.1 mm to about 0.8 mm, from about 0.1mm to about 0.75 mm, from about 0.1 mm to about 0.7 mm, from about 0.1mm to about 0.65 mm, from about 0.1 mm to about 0.6 mm, from about 0.1mm to about 0.55 mm, from about 0.1 mm to about 0.5 mm, from about 0.1mm to about 0.4 mm, or from about 0.3 mm to about 0.7 mm.

The second glass substrate may have the same glass composition as theglass substrate 140 or may differ from the glass composition used forthe glass substrate 140. In one or more embodiments, the second glasssubstrate may have an alkali-free glass composition. Suitable glasscompositions for use in the second glass substrate may include soda limeglass, alkali-free aluminosilicate glass, alkali-free borosilicateglass, alkali-free boroaluminosilicate glass, alkali-containingaluminosilicate glass, alkali-containing borosilicate glass, andalkali-containing boroaluminosilicate glass. In one or more embodiments,the second glass substrate may be strengthened (as disclosed herein withrespect to the glass substrate 140). In some embodiments, the secondglass substrate is unstrengthened or strengthened only by mechanicaland/or thermal strengthening (i.e., not strengthened by chemicalstrengthening). In some embodiments, the second glass substrate may beannealed.

In one or more embodiments, the display module 150 includes a frame 158.In the embodiment shown, the frame 158 is positioned between thebacklight unit 154 and the second glass substrate 152. The frame mayhave an “L” shape with flanges 159 extending outward from the displaymodule 150. In one or more embodiments, the frame 158 at least partiallysurrounds the backlight unit 154. In one or more embodiments as shown inFIG. 6 , the frame at least partially surrounds the second glasssubstrate 152. In one or more embodiments, the frame can either at leastpartially surrounds the minor surface 146 of the glass substrate 140 orthe minor surface of the glass substrate may not be surrounded by theframe. In other words, the frame may include secondary flanges 157 thatextend to partially surround the second glass substrate 152 and/or theminor surface of the glass substrate 140.

In one or more embodiments, the curved display includes an adhesive oradhesive layer 160 between the glass substrate 140 and the displaymodule 150. The adhesive may be optically clear. In some embodiments,the adhesive is disposed on a portion of the glass substrate 140 and/orthe display module 150. For example, as shown in FIG. 4 , the glasssubstrate may include a periphery 147 adjacent the minor surface 146defining an interior portion 148, and the adhesive may be disposed on atleast a portion of the periphery. The thickness of the adhesive may betailored to ensure lamination between the display module 150 (and moreparticularly the second glass substrate) and the glass substrate 140.For example, the adhesive may have a thickness of about 1 mm or less. Insome embodiments, the adhesive has a thickness in a range from about 200μm to about 500 μm, from about 225 μm to about 500 μm, from about 250 μmto about 500 μm, from about 275 μm to about 500 μm, from about 300 μm toabout 500 μm, from about 325 μm to about 500 μm, from about 350 μm toabout 500 μm, from about 375 μm to about 500 μm, from about 400 μm toabout 500 μm, from about 200 μm to about 475 μm, from about 200 μm toabout 450 μm, from about 200 μm to about 425 μm, from about 200 μm toabout 400 μm, from about 200 μm to about 375 μm, from about 200 μm toabout 350 μm, from about 200 μm to about 325 μm, from about 200 μm toabout 300 μm, or from about 225 μm to about 275 μm.

In one or more embodiments, the either one of or both the first majorsurface 142 and the second major surface 144 of the glass substrateincludes a surface treatment. The surface treatment may cover at least aportion of the first major surface 142 and the second major surface 144.Exemplary surface treatments include an easy-to-clean surface, ananti-glare surface, an anti-reflective surface, and a pigment design. Inone or more embodiments, the at least a portion of the first majorsurface and 142/or the second major surface 144 may include any one, anytwo or all three of an anti-glare surface, an anti-reflective surface,and a pigment design. For example, first major surface 142 may includean anti-glare surface and the second major surface 144 may include ananti-reflective surface. In another example, the first major surface 142includes an anti-reflective surface and the second major surface 144includes an anti-glare surface. In yet another example, the first majorsurface 142 comprises either one of or both the anti-glare surface andthe anti-reflective surface, and the second major surface 144 includesthe pigment design.

The pigment design may include any aesthetic design formed from apigment (e.g., ink, paint and the like) and can include a wood-graindesign, a brushed metal design, a graphic design, a portrait, or a logo.The pigment design may be printed onto the glass substrate. In one ormore embodiments, the anti-glare surface includes an etched surface. Inone or more embodiments, the anti-reflective surface includes amulti-layer coating. In one or more embodiments, the easy-to-cleansurface includes an oleophobic coating that imparts anti-fingerprintproperties.

In one or more embodiments, the surface treatment (i.e., theeasy-to-clean surface, the anti-glare surface, the anti-reflectivesurface and/or the pigment design) is disposed on at least a portion ofthe periphery 147 and the interior portion 148 is substantially free ofthe surface treatment.

In one or more embodiments, the display module includes touchfunctionality and such functionality is accessible through the glasssubstrate 140. In one or more embodiments, displayed images or contentshown by the display module is visible through the glass substrate 140.

A second aspect of this disclosure pertains to various methods andsystems for cold-bending a glass sheet/substrate, such as substrate 140,and/or forming a curved display. In various embodiments, the methods andsystems discussed herein utilize air pressure differentials to causebending of the glass sheet/substrate. As noted above, these systems andmethods bend the glass sheet/substrate without use of the hightemperatures (e.g., temperatures greater than the glass transitiontemperature) that are typical with hot-bending/hot-forming processes.

Referring to FIGS. 8 and 9 , a method 1000 of forming a curved displayis shown according to exemplary embodiments. In one or more embodiments,the method includes a step 1100 of cold-forming a glass substrate, suchas substrate 140, to a first radius of curvature (as described herein),and laminating a display module 150 to the first one of the majorsurfaces 142 or 144 (see FIGS. 2 and 3 ) while maintaining the firstradius of curvature in the glass substrate to form the curved display,wherein the display module has a second radius of curvature (asdescribed herein) that is within 10% of the first radius of curvature.As shown in FIG. 9 , in one or more embodiments, cold-forming the glasssubstrate 140 includes applying a vacuum to the second major surface 144of the glass substrate to generate the first radius of curvature 1120.Accordingly, in the embodiment shown in FIG. 9 , applying the vacuumincludes placing the glass substrate on a vacuum fixture 1110 beforeapplying the vacuum to the second major surface. To maintain the firstradius of curvature, the glass substrate and subsequent assembly withthe display module (steps 1150, 1200) is performed while the vacuum isapplied to the glass substrate to cold-form the glass substrate to thefirst radius of curvature. In other words, the glass substrate 140 istemporarily cold-formed by applying the vacuum, and subsequentlamination with the display module 150 permanently cold-forms the glasssubstrate and forms the curved display. In such embodiments, the displaymodule provides the rigidity needed to permanently cold-form the glasssubstrate. Other mechanisms to temporarily cold-form the glass substratemay be used. For example, the glass substrate may be temporarily affixedto a mold having the desired curvature to cold-form the glass substrate.The glass substrate may be temporarily affixed by a pressure sensitiveadhesive or other mechanism.

After cold-forming the glass substrate, the method of one or moreembodiments includes laminating an adhesive to the first major surface142 of the glass substrate 140 before laminating the display module tothe first major surface such that the adhesive is disposed between thefirst major surface and the display module. In one or more embodiments,laminating the adhesive may include applying a layer of the adhesive andthen applying a normal force using roller or other mechanism. Exemplaryexamples include any suitable optically clear adhesive for bonding theglass substrate to the second glass substrate of the display module 150.In one example, the adhesive may include an optically clear adhesiveavailable from 3M Corporation under the trade name 8215. The thicknessof the adhesive may be in a range from about 200 μm to about 500 μm.

In one or more embodiment, step 1200 of laminating a display moduleincludes laminating the second glass substrate 152 to the glasssubstrate 140 (step 1210 in FIG. 9 ) and then attaching the backlightunit 154 to the second glass substrate (step 1220, in FIG. 9 ). In oneor more embodiments, the method includes cold-forming the second glasssubstrate during lamination to the glass substrate. In one or moreembodiments, the second glass substrate is curved prior to lamination.For example, the second glass substrate may be temporarily curved orcold-formed before lamination to exhibit the second radius of curvature.In another example, the second glass substrate may be permanently curved(by, for example, hot forming) to exhibit the second radius ofcurvature). In one or more embodiments, the backlight unit is curved toexhibit the second radius of curvature. In one or more embodiments, thebacklight unit is flexible and is curved during lamination to the secondradius of curvature. In one or more embodiments, the backlight unit maybe curved prior to lamination. For example, the backlight unit may betemporarily curved before lamination to exhibit the second radius ofcurvature. In another example, the backlight unit may be permanentlycurved to exhibit the second radius of curvature).

In one or more embodiments, step 1220 includes attaching a frame withthe backlight unit to the second glass substrate. In one or moreembodiments, the method includes step 1230 of removing the vacuum fromthe second major surface of glass substrate 140. For example, removingthe vacuum from the second major surface may include removing the curveddisplay from the vacuum fixture.

In one or more embodiments, the method includes disposing or assemblingthe curved display in a vehicle interior system 100, 200, 300.

Referring to FIGS. 10-15 , additional systems and methods for forming acurved glass sheet/substrate via cold-forming is shown and described. Inthe specific embodiments shown and described, the curved glass substrateis utilized for a curved display for a vehicle, such as in vehicleinterior system 100, 200, 300. It should be understood that any of theglass substrate, frame, and display module embodiments described hereinmay be formed or utilized in the processes and systems discussed inrelation to FIGS. 10-15 .

Referring to FIG. 10 , a method 1300 for cold-bending a glass substrateis shown. At step 1310, a glass substrate, such as glass substrate 140,is supported and/or placed on a curved frame. The frame may be a frameof a display, such as frame 158 that defines a perimeter and curvedshape for a vehicle display. In general, the curved frame includes acurved support surface and one of the major surfaces 142 or 144 of glasssubstrate 140 is placed into contact with the curved support surface ofthe frame.

At step 1320, an air pressure differential is applied to the glasssubstrate while it is supported by the frame causing the glass substrateto bend into conformity with the curved shape of the curved supportsurface of the frame. In this manner, a curved glass substrate is formedfrom a generally flat glass substrate/sheet (see FIGS. 3 and 4 ). Inthis arrangement, curving the flat piece of glass material forms acurved shape on the major surface facing the frame, while also causing acorresponding (but complimentary) curve to form in the major surface ofthe glass substrate opposite of the frame. Applicant has found that bybending the glass substrate directly on the curved frame, the need for aseparate curved die or mold (typically needed in other glass bendingprocesses) is eliminated. Further, Applicant has found that by shapingthe glass substrate directly to the curved frame, a wide range of glassradii may be achieved in a low complexity manufacturing process.

In some embodiments, the vacuum may be generated by a vacuum fixture,such as fixture 1110. In some other embodiments, the air pressuredifferential is formed by applying a vacuum to an airtight enclosuresurrounding the frame and the glass substrate. In specific embodiments,the airtight enclosure is a flexible polymer shell, such as a plasticbag or pouch. In other embodiments, the air pressure differential isformed by generating increased air pressure around the glass substrateand the frame with an overpressure device, such as an autoclave.Applicant has further found that air pressure provides a consistent andhighly uniform bending force (as compared to a contact-based bendingmethod) which further leads to a robust manufacturing process.

At step 1330, the temperature of the glass substrate is maintained belowthe glass transition temperature of the material of the glass substrateduring bending. As such, method 1300 is a cold-forming or cold-bendingprocess. In particular embodiments, the temperature of the glasssubstrate is maintained below 500 degrees C., 400 degrees C., 300degrees C., 200 degrees C. or 100 degrees C. In a particular embodiment,the glass substrate is maintained at or below room temperature duringbending. In a particular embodiment, the glass substrate is not activelyheated via a heating element, furnace, oven, etc. during bending, as isthe case when hot-forming glass to a curved shape.

As noted above, in addition to providing processing advantages such aseliminating expensive and/or slow heating steps, the cold-formingprocesses discussed herein are believed to generate curved glass sheetswith a variety of properties that are superior to hot-formed glasssheets, particularly for display cover glass applications. For example,Applicant believes that, for at least some glass materials, heatingduring hot-forming processes decreases optical properties of curvedglass sheets, and thus, the curved glass substrates formed utilizing thecold-bending processes/systems discussed herein provide for both curvedglass shape along with improved optical qualities not believedachievable with hot-bending processes.

Further, many glass coating materials (e.g., anti-glare coatings,anti-reflective coatings, etc.) are applied via deposition processes,such as sputtering processes that are typically ill-suited for coatingcurved glass articles. In addition, many coating materials also are notable to survive the high temperatures associated with hot-bendingprocesses. Thus, in particular embodiments discussed herein, one or morecoating material is applied to major surface 142 and/or to major surface144 of glass substrate 140 prior to cold-bending, and the coated glasssubstrate is bent to a curved shape as discussed herein. Thus, Applicantbelieves that the processes and systems discussed herein allow forbending of glass after one or more coating material has been applied tothe glass, in contrast to typical hot-forming processes.

Referring to FIG. 11 , a process 1400 for forming a curved display isshown. At step 1410 an adhesive material is applied between a curvedsupport surface of the frame and first major surface 142 of glasssubstrate 140. In a particular embodiment, the adhesive is placed firstonto the frame support surface, and then at step 1420, glass substrate140 is placed onto the adhesive coated frame. In another embodiment, theadhesive may be placed onto first major surface 142 which is then placedinto contact with the support surface of the frame.

The adhesive material may be applied in a variety ways. In oneembodiment, the adhesive is applied using an applicator gun and mixingnozzle or premixed syringes, and spread uniformly using any of thefollowing, for example, a roller, a brush, a doctor blade or a draw downbar. In various embodiments, the adhesives discussed herein arestructural adhesives. In particular embodiments, the structuraladhesives may include, but not limited to, an adhesive selected from oneof more of the categories: (a) Toughened Epoxy (for example, MasterbondEP21TDCHT-LO, 3M Scotch Weld Epoxy DP460 Off-white); (b) Flexible Epoxy(for example, Masterbond EP21TDC-2LO, 3M Scotch Weld Epoxy 2216); (c)Acrylics and/or Toughened Acrylics (for example, LORD Adhesive 403, 406or 410 Acrylic adhesives with LORD Accelerator 19 or 19 GB w/ LORD AP134 primer, LORD Adhesive 850 or 852/LORD Accelerator 25 GB, LoctiteHF8000, Loctite AA4800); (d) Urethanes (for example, 3M Scotch WeldUrethane DP640 Brown, Sikaflex 552 and Polyurethane (PUR) Hot Meltadhesives such as, Technomelt PUR 9622-02 UVNA, Loctite HHD 3542,Loctite HEM 3580, 3M Hotmelt adhesives 3764 and 3748); and (e) Silicones(Dow Corning 995, Dow Corning 3-0500 Silicone Assembly adhesive, DowCorning 7091, SikaSil-GP). In some cases, structural adhesives availableas sheets or films (for example, but not limited to, 3M Structuraladhesive films AF126-2, AF 163-2M, SBT 9263 and 9214, MasterbondFLM36-LO) may be utilized. Furthermore, pressure sensitive structuraladhesives such as 3M VHB tapes may be utilized. In such embodiments,utilizing a pressure sensitive adhesive allows for the curved glasssubstrate to be bonded to the frame without the need for a curing step.

At step 1420, a variety of different techniques or mechanisms can beutilized to align the glass substrate with the frame. For example, tabs,markings and clamps can be utilized to align the glass substrate withthe frame support surface.

At step 1430, an air pressure differential is applied to cause glasssubstrate 140 to bend into conformance with the shape of curved supportsurface of the curved frame, as discussed above regarding step 1320. Atstep 1440, the now curved glass substrate is bonded to the curved framesupport surface via the adhesive. Because the air pressure does notpermanently deform the glass substrate, the bonding step occurs duringapplication of the air pressure differential. In various embodiments,the air pressure differential is between 0.5 and 1.5 atmospheres ofpressure (atm), specifically between 0.7 and 1.1 atm, and morespecifically is 0.8 to 1 atm.

Performance of step 1440 is based upon the type of adhesive used tocreate the bond between the glass substrate and the frame. For example,in embodiments where increasing the temperature will accelerate the cureof the adhesive, heat is applied to cure the adhesive. In one suchembodiment, the heat-curable adhesive is cured by raising thetemperature to the cure temperature of the adhesive but lower than theglass transition temperature of the glass substrate, while the glasssheet is held bent in conformance with the shape of curved supportsurface of the curved frame via the pressure differential. In a specificembodiment, the heat may be applied using an oven or a furnace. Inanother embodiment, both heat and pressure may be applied via anoverpressure device, such as an autoclave.

In embodiments where the adhesive is a UV-curable adhesive, UV light isapplied to cure the adhesive. In other embodiments, the adhesive is apressure sensitive adhesive, pressure is applied to bond the adhesivebetween the glass substrate and the frame. In various embodiments,regardless of the process by which the bond between the glass substrateand the frame is formed, the adhesive may be an optically clearadhesive, such as a liquid optically clear adhesive.

At step 1450, a display module, such as display module 150, is attachedto the frame supporting the now curved and bonded glass substrate. Inspecific embodiments, the glass substrate-frame assembly may be removedfrom the device applying the pressure differential, prior to attachmentof the display module to the frame. In a specific embodiment, thedisplay module is attached to the frame via an adhesive such as anoptically clear adhesive. In other embodiments, the display module maybe attached to the frame by a variety of mechanical coupling devices,such as screws, snap-fit components, etc. In a specific embodiment, aliquid optically clear adhesive (LOCA) available from E3 Display atthickness of 125 um is applied to bond the display module to the frameand then the adhesive is UV cured to obtain the assembled part.

FIG. 12 shows a graphical representation of process 1400 includingadditional steps according to an exemplary embodiment. At step 1425, theglass substrate supported on the frame is positioned within an airtightenclosure, shown as plastic vacuum bag 1426. In a specific embodiment, abreather cloth is placed on the frame 158/glass substrate 140 to provideconnectivity of the part surface to the vacuum port. Additionally, thebreather cloth helps in absorbing excess glue that may ooze out of thepart during the process.

Then at step 1430 a vacuum is drawn within vacuum bag 1426. At step1440, the vacuum bag 1426 with the glass substrate and frame arepositioned within an autoclave 1442 which generates heat to cure theadhesive bonding the glass substrate to the frame. In a specificembodiment, vacuum bag 1426 is placed in the autoclave at 66 degreesC./90 psi for 1 hour duration to cure the adhesive. At step 1460,following display module attachment at step 1450, an assembled displayassembly 1470 including the glass substrate (e.g., cover glass), displayframe, and display module is completed with all parts attached togetherand is ready for mounting in a vehicle interior.

Referring to FIG. 13 , a process 1500 for forming a curved display isshown according to another embodiment. Process 1500 is substantially thesame as process 1400, except as discussed herein. Rather than attach thedisplay module to the frame following bending and following attachmentof the glass substrate to the frame, process 1500 attaches the displaymodule to the frame beforehand, at step 1510. In some such embodiments,the display module is bonded to frame via an adhesive that is curedduring the same cure step that bonds the glass substrate to the frame.In such embodiments, the display module is bonded to the frame duringapplication of the air pressure differential that causes the bending ofglass substrate to the frame.

Referring to FIGS. 14 and 15 , display assembly 1470 is shown accordingto an exemplary embodiment. In the embodiment shown, the displayassembly includes frame 158 supporting both a display module 150 and acover glass sheet, glass substrate 140. As shown in FIGS. 14 and 15 ,both display module 150 and glass substrate 140 are coupled to frame158, and display module 150 is positioned to allow a user to viewdisplay module 150 through glass substrate 140. In various embodiments,frame 158 may be formed from a variety of materials that include, butnot limited to plastics such as polycarbonate (PC), polypropylene (PP),Acrylonitrile-Butadiene-Styrene (ABS), PC/ABS blends, etc.), metals(Al-alloys, Mg-alloys, Fe-alloys, etc.), glass-filled resins, fiberreinforced plastics and fiber reinforced composites. Various processessuch as casting, machining, stamping, injection molding, extrusion,pultrusion, resin transfer molding etc. may be utilized to form thecurved shape of frame 158.

In another example, toughened epoxy adhesive (supplied by 3M under thetradename 3M Scotch Weld Epoxy DP460 Off-white) was applied to a majorsurface of a glass substrate or on a curved frame using an applicatorgun and mixing nozzle. A roller or brush was used to spread the adhesiveuniformly. The glass substrate and frame were stacked or assembled suchthat the adhesive layer is between the glass substrate and the frame. Ahigh temperature resistant tape was then applied to temporarily maintainthe stack alignment. The stack was then placed in a vacuum bag. In thisparticular example, a release cloth (optional) was placed over the stackto prevent sticking to the vacuum bag, and then a breather cloth wasplaced over to provide connectivity of the part surface to the vacuumport, and finally, the stack, release cloth and breather cloth assemblywas placed in a vacuum bag. The vacuum bag was then sealed to withstand760 mm of Hg. The vacuum bag was then deaired by drawing a vacuum duringwhich the glass substrate was bent to conform to the curved shape offrame support surface. The vacuum bag with the curved glass substrateand supporting frame were placed in an autoclave at 66 degrees C./90 psifor 1 hour duration to cure the adhesive. The glass substrate is bondedto the curved frame support surface via the cured adhesive. Theautoclave was then cooled down to a temperature below 45° C. before thepressure was released. The curved glass substrate/frame stack wasremoved from the vacuum bag. The resulting curved glass substratemaintained the curved shape of the frame, with no delamination visibleto the naked eye. A display module may be assembled to the stack toprovide a curved display assembly

It should be understood that the adhesive may be applied and thecold-formed stack can be assembled with the curing of the adhesiveeither at room temperature or at elevated temperature or using UVdepending on the cure schedule of the particular adhesive. In someembodiments, pressure may be applied, along with heat. In someinstances, heat alone is applied to the stack. In one or moreembodiments, heat may be applied such that the temperature of the stackis in a range from greater than room temperature (i.e., 23° C.) up to300° C., from about 25° C. to about 300° C., from about 50° C. to about300° C., from about 75° C. to about 300° C., from about 100° C. to about300° C., from about 110° C. to about 300° C., from about 115° C. toabout 300° C., from about 120° C. to about 300° C., from about 150° C.to about 300° C., from about 175° C. to about 300° C., from about 200°C. to about 300° C., from about 25° C. to about 250° C., from about 25°C. to about 200° C., from about 25° C. to about 150° C., from about 25°C. to about 125° C., from about 25° C. to about 115° C., from about 25°C. to about 110° C., or from about 25° C. to about 100° C. The stack maybe heated to such temperatures for a duration from about 2 seconds toabout 24 hours, 10 seconds to about 24 hours, from about 30 seconds toabout 24 hours, from about 1 minute to about 24 hours, from about 10minutes to about 24 hours, from about 15 minutes to about 24 hours, fromabout 20 minutes to about 24 hours, from about 30 minutes to about 24hours, from about 1 hour to about 24 hours, from about 1.5 hours toabout 24 hours, from about 2 hours to about 24 hours, from about 3 hoursto about 24 hours, from about 2 seconds to about 4.5 hours, from about 2seconds to about 4 hours, from about 2 seconds to about 3 hours, fromabout 2 seconds to about 2 hours, from about 2 seconds to about 1.5hours, from about 2 seconds to about 1 hour, from about 2 seconds toabout 45 minutes, from about 2 seconds to about 30 minutes, from about 2seconds to about 15 minutes, from about 2 seconds to about 10 minutes,from about 10 minutes to about 45 minutes, or from about 15 minutes toabout 45 minutes.

In various embodiments, the systems and methods described herein allowfor formation of glass substrate to conform to a wide variety of curvedshapes that frame 158 may have. As shown in FIG. 14 , frame 158 has asupport surface 155 that has a curved shape to which glass substrate 140is shaped to match. In the specific embodiment shown in FIGS. 14 and 15, support surface 155 includes a convex section 161 and a concavesection 163, and glass substrate 140 is shaped to conform to the curvedshapes of sections 161 and 163.

As will be generally understood, the opposing first and second majorsurfaces of glass substrate 140 both form curved shapes as glasssubstrate is bent to conform to the curved shape of frame supportsurface 155. Referring to FIG. 15 , a first major surface 1471 of glasssubstrate 140 is the surface in contact with frame support surface 155,and during bending adopts the complementary shape of opposing shape ofsupport surface 155, while an outer, second major surface 1472 of glasssubstrate 140 adopts a curved shape that generally matches the curvedshape support surface 155. Thus, in this arrangement, second majorsurface 1472 has a convex section at the position of convex section 161of frame support surface 155 and has a concave section at the positionof concave section 163 of support surface 155. Conversely, first majorsurface 1471 has a concave section at the position of convex section 161of frame support surface 155 and has a convex section at the position ofconcave section 163 of support surface 155.

In specific embodiments, the radius of curvature of convex curve 161 is250 mm, and the radius of concave curve 163 is 60 mm. In someembodiments, a non-curved central section is located between the twocurved sections. Further, in some embodiments, glass substrate 14 ischemically strengthened aluminosilicate glass with a thickness of 0.4mm.

It should be understood that FIGS. 14 and 15 provide a specific exampleof a glass substrate formed with more than one curved section, but invarious embodiments, the processes and systems discussed herein can beused to form a wide variety of curved substrates having more or lesscurved sections than shown in FIGS. 14 and 15 . Further, it should beunderstood that while the exemplary embodiments discussed herein aredescribed primarily in relation to bending display cover glass, glasssubstrate 140 may be formed for any non-display curved glassapplication, such as cover glass for an instrument panel in a vehicle.

Referring to FIGS. 16A-16I, another aspect of this disclosure pertainsto kits and methods for assembling such kits to provide a curveddisplay. FIGS. 16A-16I show a concave curvature with the cold-formedglass 2010 disposed between a viewer and the display. In one or moreembodiments, the curvature may be convex, or may have a combination ofconvex and concave portions having the same or different radii from oneanother. Referring to FIGS. 16A-16C, a kit 2000 according to one or moreembodiments includes a cold-formed glass substrate 2010 (as describedherein according to one or more embodiments) and a frame 2020. In one ormore embodiments, the cold-formed glass substrate includes a first majorsurface 2012, a second major surface 2014 opposing the first majorsurface and a minor surface 2016 connecting the first major surface andthe second major surface, a thickness defined as a distance between thefirst major surface and the second major surface, a width defined as afirst dimension of one of the first or second major surfaces orthogonalto the thickness, and a length defined as a second dimension of one ofthe first or second major surfaces orthogonal to both the thickness andthe width wherein the second major surface 2014 comprises a first radiusof curvature. In the embodiments shown in FIGS. 16A-16F, the secondmajor surface forms a concave surface that exhibits a greatercompressive stress than the same surface exhibits prior to cold-forming.In some embodiments, the second major surface exhibits a greatercompressive stress than the first major surface. The frame 2020 has acurved surface 2022 that is coupled to the second major surface of thecold-formed glass substrate. In one or more embodiments, the curvedsurface 2022 may have substantially the same radius of curvature as thefirst radius of curvature. In one or more embodiments, the curvedsurface 2022 has the same radius of curvature as the first radius ofcurvature. The thickness of the cold-formed glass substrate is about 1.5mm or less. In one or more embodiments, the width of the cold-formedglass substrate is in a range from about 5 cm to about 250 cm, and thelength of the cold-formed glass substrate is from about 5 cm to about250 cm. In one or more embodiments, the first radius of curvature is 500nm or greater.

In one or more embodiments, the kit includes a display module. As shownin the embodiment of FIG. 16B and FIG. 16C, the display module includesa display including a second glass substrate 2030, and an optionalback-light unit (BLU) 2040. In some embodiments, the display moduleincludes only a display (with no BLU 2040), as shown in FIG. 16E. Insuch embodiments, the BLU may be provided separately, and attached tothe display, as shown in FIG. 16F. In one or more embodiments, thedisplay may be liquid crystal display or an organic light-emitting diode(OLED) display. In one or more embodiments, the kit may include a touchpanel instead of the display module or in addition to the display module(with the touch panel positioned to be disposed between the cold-formedglass substrate and the display module). In the embodiments shown inFIGS. 16B and 16C, the display or touch panel comprises a second glasssubstrate 2030 that is curved. In such embodiments, the second glasssubstrate comprises a curved display surface or curved touch panelsurface having a second radius of curvature that is within 10% of thefirst radius of curvature. In some embodiments, such as shown in FIGS.16C, 16E, 16F, 16H and 16I, the kit includes an adhesive layer 2050 forattachment of the second glass substrate 2030 to the cold-formed glasssubstrate or the frame. The adhesive layer may be disposed on thecold-formed glass substrate on the surface thereof to be attached to thesecond glass substrate. In the embodiment shown in FIGS. 16A-16I, theadhesive layer is disposed on the first major surface). In one or moreembodiments, the adhesive layer may be disposed on the second glasssubstrate or both the cold-formed glass substrate and the second glasssubstrate. The adhesive 2050 may be an optically clear adhesive, such asthe optically clear adhesives described herein. In one or moreembodiments, after the cold-formed substrate 2010 and the curved secondglass substrate 2030 are laminated, it is believed that such laminationexerts lower stress on any adhesive layer disposed therein. In one ormore embodiments, the second radius of curvature may be within 5%,within 4%, within 3% or within 2% of the first radius of curvature. Insome embodiments, the cold-formed glass substrate (and correspondingframe) and the second glass substrate are substantially aligned suchthat less than 2% of the width, less than 2% of the length or less than2% of both the width and the length of the cold-formed glass isunaligned with the curved second glass substrate (i.e., unalignedportions are exposed), after lamination. In one or more embodiments,less than 5% of the surface area of the first major surface 2012 isunaligned with the second glass substrate or exposed after lamination.In some embodiments, the thickness of the adhesive may be increased toenhance alignment between the cold-formed glass substrate and the secondglass substrate.

As shown in FIG. 16C, 16E, 16F, 16H or 16I, the kit may include a secondglass substrate that is attached to the first major surface 2012. In oneor more embodiments, the second glass substrate is attached to the frame2020 (not shown). A shown in the embodiments of FIGS. 16D and 16G, thesecond glass substrate 2030 is substantially flat and is cold-formableto a second radius of curvature that is within 10% of the first radiusof curvature. As shown in FIGS. 16D through 16F, the second glasssubstrate may be cold-formed to the second radius of curvature andattached to the cold-formed glass substrate or, optionally, the frame(not shown). In such embodiments, the second glass substrate 2030 or thecold-formed glass substrate 2010 may comprises an adhesive layer toattach the second glass substrate to the cold-formed glass substrate orthe frame, as applicable. In one or more particular embodiments, thefirst major surface 2012 includes an adhesive disposed thereon. In suchembodiments, the adhesive may be an optically clear adhesive that is acomposite or exhibits different Young's modulus values on the surface incontact with or adjacent the first major surface, than the oppositesurface that contacts or will contact the second glass substrate. It isbelieved that the second glass substrate may exert lower stress on theadhesive layer and thus a lower bending force may be required tocold-form the second glass substrate to the cold-formed glass substrate.In some such embodiments, the cold-formed glass substrate and the secondglass substrate are substantially aligned such that less than 2% of thewidth, less than 2% of the length or less than 2% of both the width andthe length of the cold-formed glass is unaligned with the second glasssubstrate (i.e., unaligned portions are exposed), after lamination. Inone or more embodiments, less than 5% of the surface area of the firstmajor surface 2012 is unaligned with the second glass substrate orexposed after lamination.

As shown in FIGS. 16B-16C and 16F, the BLU may be curved. In someembodiments, the BLU exhibits a third radius of curvature that is within10% of the first radius of curvature, within 10% of the second radius ofcurvature, or within 10% of the first radius of curvature and the secondradius of curvature.

In the embodiments shown in FIGS. 16H-16I, the display comprises asecond glass substrate that is substantially flat and is attached to thefirst major surface. In such embodiments, the second glass substrate orthe cold-formed glass substrate comprises an adhesive layer 2050 thatattaches the second glass substrate to the cold-formed glass substrate(i.e., either directly to the first major surface or a portion of theframe). In such embodiments, the adhesive attaches a cold-formed glasssubstrate to a flat second glass substrate. A shown, in one or moreembodiments, the adhesive layer comprises a first surface that issubstantially flat and an opposing second surface having a second radiusof curvature that is within the 10% of the first radius of curvature. Insuch embodiments, the adhesive may be a liquid optically clear adhesive.In some embodiments, the first radius of curvature is in a range fromabout 500 nm to about 1000 nm.

In one or more embodiments, in the kit shown in FIGS. 16A-16I, an airgap may be present between the second glass substrate and thecold-formed glass substrate (i.e., the first major surface). In one ormore embodiments, the adhesive layer may be present on only a portion ofthe cold-formed glass substrate and/or the second glass substrate suchthat there is no attachment between a portion of the cold-formed glasssubstrate and the second glass substrate (as there is no adhesivepresent to form such attachment).

FIGS. 17A-17I illustrate various embodiments of a kit 3000 that includesa frame 3020 that is removable or is temporarily attached to acold-formed glass substrate 3010. FIGS. 17A-17I show a convex curvaturewith the cold-formed glass 3010 disposed between a viewer and thedisplay. In one or more embodiments, the curvature may be concave, ormay have a combination of convex and concave portions having the same ordifferent radii from one another. In one or more embodiments, the kitincludes a cold-formed glass substrate 3010 comprises a first majorsurface 3012, a second major surface 3014 opposing the first majorsurface having a first radius of curvature, and a minor surfaceconnecting the first major surface and the second major surface, athickness defined as a distance between the first major surface and thesecond major surface, a width defined as a first dimension of one of thefirst or second major surfaces orthogonal to the thickness, and a lengthdefined as a second dimension of one of the first or second majorsurfaces orthogonal to both the thickness and the width, wherein thesecond major surface comprises a first radius of curvature, and aremovable frame 3020 removably coupled to the second major surface. Inone or more embodiments, the frame has a curved surface that is coupledto the second major surface. The curved surface of the frame may havethe same radius of curvature as the first radius of curvature. In theembodiments shown in FIGS. 17A-17I, the second major surface forms aconcave surface that exhibits a greater compressive stress than the samesurface exhibits prior to cold-forming. In some embodiments, the secondmajor surface exhibits a greater compressive stress than the first majorsurface.

The thickness of the cold-formed glass substrate is about 1.5 mm orless. In one or more embodiments, the width of the cold-formed glasssubstrate is in a range from about 5 cm to about 250 cm, and the lengthof the cold-formed glass substrate is from about 5 cm to about 250 cm.In one or more embodiments, the first radius of curvature is 500 nm orgreater.

In one or more embodiments shown in FIGS. 17A-17I, the kit includes adisplay module. As shown in FIG. 17B and FIG. 17C, the display moduleincludes a display including a second glass substrate 3030, and anoptional back-light unit (BLU) 3040. In some embodiments, the displaymodule includes only a display (with no BLU 3040), as shown in FIG. 17E.In such embodiments, the BLU or other mechanism or structure may beprovided separately, and attached as shown in FIG. 17F to maintain thecurved shape of the cold-formed glass substrate and the second glasssubstrate after the removable frame is removed. In one or moreembodiments, the display may be liquid crystal display or an organiclight-emitting diode (OLED) display. In one or more embodiments, the kitmay include a touch panel instead of the display module or in additionto the display module (with the touch panel positioned to be disposedbetween the cold-formed glass substrate and the display module). In theembodiments shown in FIGS. 17B and 17C, the display or touch panelcomprises a second glass substrate 3030 that is curved. In suchembodiments, the second glass substrate comprises a curved displaysurface or curved touch panel surface having a second radius ofcurvature that is within 10% of the first radius of curvature. In one ormore embodiments, the second glass substrate may curved and havesufficient rigidity or structure to maintain the cold-formed shape ofthe cold-formed glass after the removable frame is removed. In someembodiments, such as shown in FIGS. 17C, 17E, 17F, 17H and 17I, the kitcomprises an adhesive layer 3050 for attachment of the second glasssubstrate to the cold-formed glass substrate (and specifically, thefirst major surface 3012). The adhesive layer may be provided on thecold-formed glass substrate (i.e., the first major surface), on thesecond glass substrate or both the cold-formed glass substrate and thesecond glass substrate. The adhesive 3050 may be an optically clearadhesive, such as the optically clear adhesives described herein. In oneor more embodiments as shown in FIGS. 17B and 17C, after the curvedcold-formed substrate 3010 and the curved second glass substrate 3030are laminated, it is believed that such lamination exerts lower stresson any adhesive layer disposed therein. In one or more embodiments,after the cold-formed substrate 3010 and the curved second glasssubstrate 3030 are laminated, the second radius of curvature may bewithin 5%, within 4%, within 3% or within 2% of the first radius ofcurvature. In some embodiments, the cold-formed glass substrate and thesecond glass substrate are substantially aligned such that less than 2%of the width, less than 2% of the length or less than 2% of both thewidth and the length of the cold-formed glass is unaligned with thesecond glass substrate (i.e., unaligned portions are exposed), afterlamination. In one or more embodiments, less than 5% of the surface areaof the first major surface 2012 is unaligned with the second glasssubstrate or exposed after lamination. In some embodiments, thethickness of the adhesive may be increased to enhance alignment betweenthe cold-formed glass substrate and the second glass substrate.

As shown in FIG. 17C, 17E, 17F, 17H or 17I, the kit may include a secondglass substrate that is attached to the first major surface 3012. Ashown in FIGS. 17D and 17G, the second glass substrate 3030 may besubstantially flat and is cold-formable to a second radius of curvaturethat is within 10% of the first radius of curvature. As shown in FIGS.17D through 17F, the second glass substrate may be cold-formed to thesecond radius of curvature and may be attached to the cold-formed glasssubstrate (i.e., the first major surface 3012). In such embodiments, thesecond glass substrate 3030 or the cold-formed glass substrate 3010 maycomprises an adhesive layer to attach the second glass substrate to thecold-formed glass substrate, as applicable. In one or more particularembodiments, the adhesive layer may be disposed on the first majorsurface. In such embodiments, the adhesive may be an optically clearadhesive that is a composite or exhibits different Young's modulusvalues on the surface in contact with or adjacent the first majorsurface, than the opposite surface that contacts or will contact thesecond glass substrate. It is believed that the second glass substratemay exert lower stress on the adhesive layer and thus a lower bendingforce is required to cold-form the second glass substrate to thecold-formed glass substrate. In some such embodiments, the cold-formedglass substrate and the second glass substrate are substantially alignedsuch that less than 2% of the width, less than 2% of the length or lessthan 2% of both the width and the length of the cold-formed glass isunaligned with the second glass substrate (i.e., unaligned portions areexposed), after lamination. In one or more embodiments, less than 5% ofthe surface area of the first major surface 2012 is unaligned with thesecond glass substrate or exposed after lamination.

As shown in FIGS. 17B-17C and 17F, a curved BLU 3040 may be attached tothe second glass substrate 3030. In some embodiments, the BLU 3040exhibits a third radius of curvature that is within 10% of the firstradius of curvature, within 10% of the second radius of curvature, orwithin 10% of the first radius of curvature and the second radius ofcurvature.

In such embodiments, the BLU 3040 provides the structure to maintain thecurved shape of the cold-formed glass substrate and the second glasssubstrate, after the removable frame is removed, as shown in FIGS. 17Cand 17F. Where a touch panel is included, a corresponding structure isattached to the second substrate opposite the surface that is attachedor will attach to the cold-formed glass substrate.

In the embodiments shown in FIGS. 17H-17I, the display comprises asecond glass substrate 3030 that is substantially flat and is attachedto the first major surface. In such embodiments, the frame 3020maintains the curved shape of the cold-formed glass substrate, and thesecond glass substrate 3030 or the cold-formed glass substrate 3010comprises an adhesive layer 3050 that attaches the second glasssubstrate to the first major surface. In such embodiments, the adhesiveattaches a cold-formed glass substrate to a flat second glass substrate.A shown, in one or more embodiments, the adhesive layer comprises afirst surface that is substantially flat and an opposing second surfacehaving a second radius of curvature that is within the 10% of the firstradius of curvature. In such embodiments, the adhesive may be a liquidoptically clear adhesive. In some embodiments, the first radius ofcurvature is in a range from about 500 nm to about 1000 nm. In suchembodiments, the adhesive layer is a structural adhesive that providesthe structure to maintain the curved shape of the cold-formed glasssubstrate after the frame is removed, as shown in FIG. 17I.

In one or more embodiments, an air gap may be present between the secondglass substrate and the cold-formed glass substrate (i.e., the firstmajor surface). In such embodiments, the adhesive layer may be presenton only a portion of the cold-formed glass substrate and/or the secondglass substrate such that there is no attachment between a portion ofthe cold-formed glass substrate and the second glass substrate (as thereis no adhesive present to form such attachment).

FIGS. 18A-18B illustrate a kit that includes a flexible glass substrate4010 that comprises a first major surface, a second major surfaceopposing the first major surface and a minor surface connecting thefirst major surface and the second major surface, a thickness defined asa distance between the first major surface and the second major surface,a width defined as a first dimension of one of the first or second majorsurfaces orthogonal to the thickness, and a length defined as a seconddimension of one of the first or second major surfaces orthogonal toboth the thickness and the width, and a curved display module 4020 or acurved touch panel having a first radius of curvature, as shown in FIG.18A. FIGS. 18A-18B show a convex curvature with the flexible glasssubstrate 4010 disposed between a viewer and the display. In one or moreembodiments, the curvature may be concave, or may have a combination ofconvex and concave portions having the same or different radii from oneanother.

The thickness of the flexible glass substrate 4010 is about 1.5 mm orless. In one or more embodiments, the width of the flexible glasssubstrate is in a range from about 5 cm to about 250 cm, and the lengthof the flexible glass substrate is from about 5 cm to about 250 cm. Inone or more embodiments, the first radius of curvature is 500 nm orgreater.

As shown in FIG. 18A and FIG. 18B, the display module includes a displayincluding a second glass substrate 4030, and a back-light unit (BLU)4040 or other structure for maintaining the curved shape of the curveddisplay module 4020. In some embodiments, the display module includesonly a display (with no BLU 4040), as shown in FIG. 16E and FIG. 18F. Insuch embodiments, the BLU or other structure may be provided separately,and attached to the display, as shown in FIG. 18G. In one or moreembodiments, the display may be liquid crystal display or an organiclight-emitting diode (OLED) display. In the embodiments shown in FIG.18B, the display comprises a second glass substrate 4030 that is curvedand exhibits the first radius of curvature. In one or more embodiments,the kit includes a curved touch panel instead of the curved displaymodule or in addition to the curved display module (with the touch panelpositioned to be disposed between the cold-formed glass substrate andthe curved display module). In such embodiments, the curved touch panelincludes a second glass substrate that is curved, and which mayoptionally provide the structural rigidity to maintain its curved shape(even after attachment to the flexible glass substrate as shown in FIG.18B). In some embodiments, the kit includes an adhesive layer 4050 forattachment of the second glass substrate 4030 to the flexible glasssubstrate 4010 (i.e., the first major surface 4012). The adhesive layermay be provided on the flexible glass substrate (i.e., the first majorsurface), on the second glass substrate or both the flexible glasssubstrate and the second glass substrate. The adhesive 4050 may be anoptically clear adhesive, such as the optically clear adhesivesdescribed herein. In one or more embodiments, after the flexible glasssubstrate is cold-formed and laminated to the curved display module ortouch panel, the second major surface 4014 exhibits a second radius ofcurvature that is within 10%, within 5%, within 4%, within 3% or within2% of the first radius of curvature. In the embodiments shown in FIG.18B, the second major surface forms a concave surface that exhibits agreater compressive stress than the same surface exhibits prior tocold-forming. In some embodiments, the second major surface exhibits agreater compressive stress than the first major surface.

In some embodiments, the resulting cold-formed glass substrate (andcorresponding frame) and the second glass substrate are substantiallyaligned such that less than 2% of the width, less than 2% of the lengthor less than 2% of both the width and the length of the cold-formedglass is unaligned with the second glass substrate (i.e., unalignedportions are exposed), after lamination. In one or more embodiments,less than 5% of the surface area of the first major surface 2012 isunaligned with the second glass substrate or exposed after lamination.In some embodiments, the thickness of the adhesive may be increased toenhance alignment between the cold-formed glass substrate and the secondglass substrate.

In one or more embodiments, after the flexible glass substrate 4010 iscold-formed and laminated to the curved second glass substrate 4030, itis believed that the stress exerted on any adhesive layer disposedtherein may be minimized by minimizing the thickness of the flexibleglass substrate (i.e., to the ranges described herein). In one or moreembodiments, the kit includes a bezel formed on the flexible glasssubstrate to reduce stress on the flexible glass substrate whencold-forming.

As shown in FIG. 18B, the second glass substrate is attached to thefirst major surface 4012. A shown in FIG. 18A, the flexible glasssubstrate 4010 is substantially flat and is cold-formable to a secondradius of curvature that is within 10% of the first radius of curvature.As shown in FIG. 18B, the flexible glass substrate is cold-formed to thesecond radius of curvature and attached to the second glass substrate.As shown in FIGS. 18A-18B, the BLU is curved and provides the structureto maintain the cold-formed shape of the second glass substrate and theflexible glass substrate (after it is cold-formed to the second glasssubstrate). In some embodiments, the BLU exhibits a third radius ofcurvature that is within 10% of the first radius of curvature, within10% of the second radius of curvature, or within 10% of the first radiusof curvature and the second radius of curvature. In some embodiments,the second glass substrate is curved and can maintain the curved shapeof the cold-formed glass substrate with the BLU or other structure.

In one or more embodiments, an air gap may be present between the secondglass substrate and the cold-formed glass substrate (i.e., the firstmajor surface). In such embodiments, the adhesive layer may be presenton only a portion of the cold-formed glass substrate and/or the secondglass substrate such that there is no attachment between a portion ofthe cold-formed glass substrate and the second glass substrate (as thereis no adhesive present to form such attachment).

FIGS. 19A-19E illustrate embodiments of a method of forming a curveddisplay.

FIGS. 19A-19E show a convex curvature; however, the curvature may beconcave, or may have a combination of convex and concave portions havingthe same or different radii from one another. In one or moreembodiments, the method 5000 includes cold-forming a stack 5001 to afirst radius of curvature as measured on a first surface 5005 of thestack. The stack may be a display stack, a touch panel stack or a stackthat includes a touch panel and display. In one or more embodiments, thedisplay may be liquid crystal display or an organic light-emitting diode(OLED) display. The stack is shown in FIG. 19A and includes a firstglass substrate 5010 having a first major surface 5012 forming the firstsurface of the display stack and a second major surface 5014 oppositethe first major surface, a display and/or touch panel module comprisinga second glass substrate 5030 disposed on the second major surface 5014.In the embodiment shown in FIG. 19A, the stack is placed on a frame 5020prior to and during cold-forming to maintain the cold-formed shape ofthe stack. In one or more embodiments, the method includes laminatingthe display and/or touch panel module to the second major surface suchthat second glass substrate comprises a second radius of curvature thatis within 10% of the first radius of curvature. In one or moreembodiments, the first radius of curvature is in a range from about 60mm to about 1500 mm. In the embodiments shown in FIGS. 19A-19E, aftercold-forming, the second major surface forms a concave surface thatexhibits a greater compressive stress than the same surface exhibitsprior to cold-forming. In some embodiments, the second major surfaceexhibits a greater compressive stress than the first major surface. Inone or more embodiments, the method includes cold-forming the stack byapplying a vacuum to the first surface to generate the first radius ofcurvature. In one or more embodiments, applying the vacuum comprisesplacing the stack on a vacuum fixture before applying the vacuum to thefirst surface. In the embodiment shown in FIG. 19A, the method includesapplying an adhesive layer 5050 between the second glass substrate andthe first glass substrate before cold-forming the stack. In someembodiments, the adhesive layer is disposed on a portion of the secondglass substrate or the first glass substrate.

In the embodiment shown in FIG. 19A, the display module may include acold-formable backlight unit 5040 disposed on the second glass substrateopposite the first glass substrate. In the embodiment shown in FIGS. 19Cthrough 19E, the module includes only a display or touch panel (with noBLU 5040). In such embodiments, the BLU or other mechanism or structuremay be provided separately, and attached to the display or touch panel,as shown in FIG. 19E to maintain the curved shape of the display stack.In some embodiments, the frame 5020 may be removed if the BLU, secondglass substrate, or other component provides adequate structure tomaintain the curved shape of the cold-formed glass substrate. In someembodiments, the frame and the BLU work together to maintain thecold-formed shape. Accordingly, in one or more embodiments, cold-formingand/or laminating a display stack comprises attaching a BLU to thesecond glass substrate opposite the first glass substrate, wherein theBLU is optionally curved to exhibit the second radius of curvature.

In one or more embodiments, the method includes attaching a frame to thefirst glass substrate to maintain the first radius of curvature, andsimultaneously cold-forming and laminating the display stack.

In one or more embodiments, the first glass substrate is strengthened.In one or more embodiments, the second glass substrate isunstrengthened. In one or more embodiments, the second glass substratehas a thickness that is greater than a thickness of the glass substrate.In one or more embodiments, the method includes disposing the curveddisplay in a vehicle interior system.

FIGS. 20A-22B relate to embodiments that address an effective stressthat may be found in a structural adhesive used in one or moreembodiments discussed herein. While structural adhesives are sufficientto hold the cold-bent glass in shape, stress is generated in theadhesive due to elastic properties and relatively high modulus of theglass substrate that can make the glass substrate want to return back toa flat, 2D shape. Under these circumstances, there will be one or moreareas of maximum stress generated in the adhesive layer. While notintending to be constrained by this theory, it is thought that some areaof the curved part of the glass substrate may have a higher tendency toretain 2D shape compared to other areas. These areas that have highertendency to return back to 2D shape lead to higher stress in theadhesive layer. This tendency can be conceptualized as a restoring forcepresent in the elastically deformed or cold-formed glass substrate. The“restoring force,” as used herein, refers to a force that tends toreturn the cold-formed or cold-bent glass substrate to the glasssubstrate's pre-bent state.

The higher stress areas in the adhesive are potential failure pointsduring the life of the product, particularly when used in the automotiveenvironment, which may require long product life times and relativelyharsh environmental conditions. For example, once a crack initiates inthe high stress area, it could propagate over a larger area or theentire area of the product. This is true for high modulus adhesivematerials that have a tendency to show brittle characteristics.Consequently, an adhesive with higher safety margin between the adhesivestresses in the part versus the adhesive strength is preferred for suchapplications. This leads to a reduced number of choices for adhesivematerials for cold-bend applications. Therefore, there is a need tominimize the peak stress in the adhesive layer.

Generally, the embodiments of FIGS. 20B, 21B, and 22B illustrate the useof one or more components, design elements, and/or methods to addressthis effective stress in the adhesive, in ways that can result incold-formed, curved glass surfaces with improved performance, adhesion,and shape retention. In addition, according to these embodiments, theabove advantages can be achieved at low cost.

As shown in FIG. 20A, a glass substrate 6010 is cold-formed to a base6020 having a curved surface with a first radius of curvature 6030. Thefirst radius of curvature 6030 can be, for example, about 500 mm ormore. In some cases, the first radius of curvature 6030 can be fromabout 60 mm to about 1500 mm. Cold-forming of the glass substrate 6010can result in an effective stress 6040 in the adhesive used between theglass substrate 6010 and the base 6020. As shown in FIG. 20A, where 6050represents an effective stress of zero, the magnitude of the effectivestress 6040 can vary over a length of the curved surface of the glasssubstrate 6010. Thus, the effective stress 6040 has areas of high stress6060, 6062. In this case, the areas of high stress 6060, 6062 includethe maximum effective stress values in the adhesive.

To mitigate the areas of high stress 6060, 6062 in FIG. 20A, astress-mitigation component. FIG. 20B shows one embodiment of astress-mitigation component in the form of mechanical restraints 6072located near the areas where the effective stress is highest. In theexample shown in FIGS. 20A, the areas of high stress 6060, 6062 are atthe edges of the glass substrate 6010. Accordingly, in FIG. 20B, themechanical restraints 6070, 6072 are placed at the edges of the glasssubstrate 6010. The mechanical restraints 6070, 6072 can be placedaround substantially an entire edge of the glass substrate 6010, or onlyat select locations determined to be most pertinent to reducing theeffective stress in the adhesive. The mechanical restraints 6070, 6072can be bezel, clamps, clips, or springs configured to reinforce or holdthe cold-bent shape of the glass substrate 6010. In some embodiments,the mechanical restraints 6070, 6072 can be made from plastic, metal, orother known materials suitable for engaging the glass substrate 6010, aslong as the mechanical restraint is configured to have mechanicalproperties to sufficient to at least partially counter any restoringforce exerted by the glass substrate 6010. Examples of thestress-mitigation component are not limited to these examples, and aperson of ordinary skill in the art would recognize suitablealternatives that can be configured to mitigate or reduce the areas ofhigh stress 6060, 6062. As shown in FIG. 20B, the mechanical restraints6070, 6072 result in an altered effective stress profile 6080 in theadhesive, without the peaks of maximum stress shown in FIG. 20A.

As shown in FIGS. 21A and 21B, according to one or more embodiments, adesign modification of the component having curved, cold-formed glasscan be used to mitigate high effective stress levels in the adhesive.FIG. 21A illustrates the cold-formed glass substrate 6010 without thedesign modification, and substantially corresponds to FIG. 20A. Forbrevity, the components of FIG. 21A discussed above with reference toFIG. 20A will not be repeated here. As shown in FIG. 21B, the designmodification includes forming the base 6020 to have a second radius ofcurvature 6032, where the second radius of curvature 6032 is larger thanthe first radius of curvature 6030. The location of the area of the basehaving the second radius of curvature 6032 corresponds to an area of theglass substrate 6010 where the adhesive would contain areas of highstress 6060, 6062, shown in FIG. 21A. In some embodiments, the secondradius of curvature is about 500 mm or more; or about 1000 mm or more;or is substantially flat. As shown in FIG. 21B, the area having thesecond radius of curvature 6032 can include more than one area orseparate areas of the base 6020. In the example of FIG. 21B, theseseparate areas correspond to edges of the glass substrate 6010. However,embodiments are not limited to these specific locations.

FIGS. 22A and 22B represent an additional approach to mitigating higheffective stress in the adhesive. In this approach, areas 7040 of theglass substrate 7010 that may correspond to areas of potentially higheffective stress in the adhesive are hot-formed. The hot-forming can beselectively performed on the areas 7040, while a remainder or anotherportion of the glass substrate can be cold-formed to the surface 7020.In some embodiments, the glass-substrate 7010 can selectivelyhot-formed, and then subsequently chemically strengthened, and finallycold-formed to the surface 7020. In the embodiment shown in FIGS. 22Aand 22B, the areas 7040 that are selectively hot-formed are areas of alocal radius of curvature that is smaller than a global radius ofcurvature 7030 of the surface 7020, where the glass substrate 7010 iscold-formed to the portion of the surface 7020 having the global radiusof curvature 7030. In some embodiments, the local radius of curvature isabout 100 mm or less and the global radius of curvature is about 500 mmor more. Embodiments include a glass substrate or component having aglass substrate, as well as methods of forming the glass substrateand/or component having the glass substrate.

The embodiments shown in FIGS. 20B, 21B, and 22B may be implementedindividually or in one or more combinations for a given curved vehicleinterior to provide enhanced reliability and adhesion of cold-bent glassusing structural adhesives.

Example 1

Example 1 included a curved display formed from a 0.55 mm thick glasssubstrate that is chemically strengthened and exhibits a first radius ofcurvature of about 1000 mm. The glass substrate was provided flat andone major surface (the second major surface) was placed on a vacuumchuck having a radius of curvature of 1000 mm. The vacuum was applied tothe major surface of the glass substrate to temporarily cold-from theglass substrate to exhibit a first radius of curvature of about 1000 mm,matching the radius of curvature of the vacuum chuck. If the vacuum wasremoved, the glass substrate would return to being flat and would nolonger be cold-formed. While the glass substrate was disposed on thevacuum chuck and temporarily cold-formed, a layer of adhesive suppliedby 3M corporation under the tradename 8215 having a thickness of 250 μmis applied to the first major surface of the glass substrate (i.e., thesurface that is exposed and not in contact with the vacuum chuck).Normal force was applied to a roller to laminate the adhesive to thefirst major surface of the cold-formed glass substrate. The adhesivelayer included a carrier film, which was removed after the adhesivelayer was laminated to the cold-formed glass substrate.

A second glass substrate (which was an LCD glass substrate) was disposedon the adhesive layer. The second glass substrate was cold-formed andlaminated to adhesive layer using a roller and applying normal force.During lamination of the second glass substrate, the glass substratecontinued to be temporarily cold-formed using the vacuum. Afterlamination of the second glass substrate, a backlight and frame wasapplied to the second glass substrate. In Example 1, a double sided tapewas applied between the frame and the glass substrate. The double sidedtape was a double-sided acrylic foam tapes supplied by 3M Corporationunder the trademark VHB™ Tapes. The frame had an L-shaped bezel. Theassembly of the frame and backlight unit completed formation of thecurved display. The vacuum was then removed from the glass substrate andthe curved display was removed. The cold-formed glass substrate waspermanently cold-formed and had a first radius of curvature. The displaymodule (and particularly the second glass substrate) exhibited a secondradius of curvature that approached or matched the first radius ofcurvature.

Aspect (1) of this disclosure pertains to a vehicle interior systemcomprising a base having a curved surface; a cold-formed glass substratedisposed on the curved surface, the glass substrate comprising a firstmajor surface, a second major surface opposing the first major surfaceand facing the curved surface, and a minor surface connecting the firstmajor surface and the second major surface, a thickness defined as adistance between the first major surface and the second major surface, awidth defined as a first dimension of one of the first or second majorsurfaces orthogonal to the thickness, and a length defined as a seconddimension of one of the first or second major surfaces orthogonal toboth the thickness and the width; an adhesive disposed between thecurved surface and the glass substrate; and at least onestress-reduction component coupled to the glass substrate in a locationthat reduces an amount of adhesive stress in one or more areas of theadhesive, wherein the thickness is 1.5 mm or less, and wherein thesecond major surface comprises a first radius of curvature of 500 mm orgreater.

Aspect (2) of this disclosure pertains to the vehicle interior system ofAspect (1), further comprising a display module attached to the firstmajor surface and comprising a second radius of curvature that is within10% of the first radius of curvature.

Aspect (3) of this disclosure pertains to the vehicle interior system ofAspect (1) or Aspect (2), wherein the width is in a range from about 5cm to about 250 cm, and the length is from about 5 cm to about 250 cm.

Aspect (4) of this disclosure pertains to the vehicle interior system ofany one of Aspects (1)-(3), wherein the cold-formed glass substrate isstrengthened.

Aspect (5) of this disclosure pertains to the vehicle interior system ofany one of Aspects (2)-(4), wherein the adhesive is disposed between theglass substrate and the display module.

Aspect (6) of this disclosure pertains to the vehicle interior system ofany one of Aspects (1)-(5), wherein the adhesive is optically clear.

Aspect (7) of this disclosure pertains to the vehicle interior system ofAspect (1) or Aspect (2), wherein the glass substrate comprises aperiphery adjacent the minor surface, and the adhesive is disposedbetween the periphery of the second major surface and the displaymodule.

Aspect (8) of this disclosure pertains to the vehicle interior system ofany one of Aspects (1)-(7), wherein the display module comprises asecond glass substrate and a backlight unit, wherein the second glasssubstrate is disposed adjacent the first major surface and between thebacklight unit and the first major surface, and wherein the backlightunit is optionally curved to exhibit the second radius of curvature.

Aspect (9) of this disclosure pertains to the vehicle interior system ofAspect (8), wherein the second glass substrate comprises a cold-formedsecond glass substrate.

Aspect (10) of this disclosure pertains to the vehicle interior systemof Aspect (8) or Aspect (9), wherein the display module furthercomprises a frame at least partially surrounding the backlight unit.

Aspect (11) of this disclosure pertains to the vehicle interior systemof Aspect (10), wherein the frame at least partially surrounds thesecond glass substrate.

Aspect (12) of this disclosure pertains to the vehicle interior systemof Aspect (10) or Aspect (11), wherein the frame at least partiallysurrounds the minor surface of the glass substrate.

Aspect (13) of this disclosure pertains to the vehicle interior systemof Aspect (10) or Aspect (11), wherein the minor surface of the glasssubstrate is not surrounded by the frame.

Aspect (14) of this disclosure pertains to the vehicle interior systemof Aspect (10), wherein the frame comprises an L-shape.

Aspect (15) of this disclosure pertains to the vehicle interior systemof any one of Aspects (1)-(14), wherein either one of or both the firstmajor surface and the second major surface comprises a surfacetreatment.

Aspect (16) of this disclosure pertains to the vehicle interior systemof Aspect (15), wherein the surface treatment covers at least a portionof the first major surface and the second major surface.

Aspect (17) of this disclosure pertains to the vehicle interior systemof Aspect (15) or Aspect (16), wherein the surface treatment comprisesany one of an easy-to-clean surface, an anti-glare surface, ananti-reflective surface, and a pigment design.

Aspect (18) of this disclosure pertains to the vehicle interior systemof Aspect (17), wherein the surface treatment comprises at least two ofany one of an easy-to-clean surface, an anti-glare surface, ananti-reflective surface, and a pigment design.

Aspect (19) of this disclosure pertains to the vehicle interior systemof Aspect (18), wherein the first major surface comprises the anti-glaresurface and the second major surface comprises the anti-reflectivesurface.

Aspect (20) of this disclosure pertains to the vehicle interior systemof Aspect (18), wherein the first major surface comprises theanti-reflective surface and the second major surface comprises theanti-glare surface.

Aspect (21) of this disclosure pertains to the vehicle interior systemof Aspect (18), wherein the first major surface comprises either one ofor both the anti-glare surface and the anti-reflective surface, and thesecond major surface comprises the pigment design.

Aspect (22) of this disclosure pertains to the vehicle interior systemof Aspect (18), wherein the pigment design is disposed on at least aportion of the periphery and the interior portion is substantially freeof the pigment design.

Aspect (23) of this disclosure pertains to the vehicle interior systemof any one of Aspects (17)-(22), wherein the pigment design comprisesany one of a wood-grain design, a brushed metal design, a graphicdesign, a portrait, and a logo.

Aspect (24) of this disclosure pertains to the vehicle interior systemof any one of Aspects (17)-(23), wherein the anti-glare surfacecomprises an etched surface, and wherein the anti-reflective surfacecomprises a multi-layer coating.

Aspect (25) of this disclosure pertains to the vehicle interior systemof any one of Aspects (1)-(24), further comprising touch functionality.

Aspect (26) of this disclosure pertains to the vehicle interior systemof any one of Aspects (1)-(25), wherein the base comprises any one of acenter console, a dashboard, an arm rest, a pillar, a seat back, a floorboard, a headrest, a door panel, and a steering wheel.

Aspect (27) of this disclosure pertains to the vehicle interior systemof any one of Aspects (1)-(26), wherein the vehicle is any one of anautomobile, a seacraft, and an aircraft.

Aspect (28) of this disclosure pertains to the vehicle interior systemof any one of Aspects (1)-(27), wherein the at least onestress-reduction component comprises a mechanical restraint.

Aspect (29) of this disclosure pertains to the vehicle interior systemof Aspect (28), wherein the mechanical restraint comprises at least oneof a bezel, a clamp, and a spring.

Aspect (30) of this disclosure pertains to the vehicle interior systemof Aspect (28), wherein the mechanical restraint is configured to exerta force on the glass substrate to maintain a cold-formed shape of theglass substrate.

Aspect (31) of this disclosure pertains to the vehicle interior systemof Aspect (30), wherein the force is directed opposite to a restoringforce of the glass substrate in the cold-formed shape.

Aspect (32) of this disclosure pertains to the vehicle interior systemof any one of Aspects (1)-(31), wherein the location of the at least onestress-reduction component comprises an edge of the first major surface.

Aspect (33) of this disclosure pertains to the vehicle interior systemof any one of Aspects (1)-(32), wherein the one or more areas of theadhesive comprises an area of maximum adhesive stress.

Aspect (34) of this disclosure pertains to the vehicle interior systemof any one of Aspects (1)-(32), wherein the one or more areas of theadhesive comprises an area having a local maximum adhesive stress.

Aspect (35) of this disclosure pertains to a vehicle interior systemcomprising a base having a curved surface; a cold-formed glass substratedisposed on the curved surface, the glass substrate comprising a firstmajor surface, a second major surface opposing the first major surfaceand facing the curved surface, and a minor surface connecting the firstmajor surface and the second major surface, a thickness defined as adistance between the first major surface and the second major surface, awidth defined as a first dimension of one of the first or second majorsurfaces orthogonal to the thickness, and a length defined as a seconddimension of one of the first or second major surfaces orthogonal toboth the thickness and the width; and an adhesive disposed between thecurved surface and the glass substrate, wherein the thickness is 1.5 mmor less, wherein the second major surface comprises a first radius ofcurvature of 500 mm or greater, and wherein the second major surfacecomprises a second radius of curvature that is greater than the firstradius of curvature.

Aspect (36) of this disclosure pertains to the vehicle interior systemof Aspect (35), further comprising a display module attached to thefirst major surface and comprising a third radius of curvature that iswithin 10% of the first radius of curvature.

Aspect (37) of this disclosure pertains to the vehicle interior systemof Aspect (35) or Aspect (36), wherein the width is in a range fromabout 5 cm to about 250 cm, and the length is from about 5 cm to about250 cm.

Aspect (38) of this disclosure pertains to the vehicle interior systemof any one of Aspects (35)-(37), wherein the cold-formed glass substrateis strengthened.

Aspect (39) of this disclosure pertains to the vehicle interior systemof any one of Aspects (36)-(38), wherein the adhesive is disposedbetween the glass substrate and the display module.

Aspect (40) of this disclosure pertains to the vehicle interior systemof any one of Aspects (35)-(39), wherein the adhesive is opticallyclear.

Aspect (41) of this disclosure pertains to the vehicle interior systemof Aspect (35) or Aspect (36), wherein the glass substrate comprises aperiphery adjacent the minor surface, and the adhesive is disposedbetween the periphery of the second major surface and the displaymodule.

Aspect (42) of this disclosure pertains to the vehicle interior systemof any one of Aspects (35)-(41), wherein the display module comprises asecond glass substrate and a backlight unit, wherein the second glasssubstrate is disposed adjacent the first major surface and between thebacklight unit and the first major surface, and wherein the backlightunit is optionally curved to exhibit the second radius of curvature.

Aspect (43) of this disclosure pertains to the vehicle interior systemof Aspect (42), wherein the second glass substrate comprises acold-formed second glass substrate.

Aspect (44) of this disclosure pertains to the vehicle interior systemof Aspect (42) or Aspect (43), wherein the display module furthercomprises a frame at least partially surrounding the backlight unit.

Aspect (45) of this disclosure pertains to the vehicle interior systemof Aspect (44), wherein the frame at least partially surrounds thesecond glass substrate.

Aspect (46) of this disclosure pertains to the vehicle interior systemof Aspect (44) or Aspect (45), wherein the frame at least partiallysurrounds the minor surface of the glass substrate.

Aspect (47) of this disclosure pertains to the vehicle interior systemof Aspect (44) or Aspect (45), wherein the minor surface of the glasssubstrate is not surrounded by the frame.

Aspect (48) of this disclosure pertains to the vehicle interior systemof Aspect (44), wherein the frame comprises an L-shape.

Aspect (49) of this disclosure pertains to the vehicle interior systemof any one of Aspects (35)-(48), wherein either one of or both the firstmajor surface and the second major surface comprises a surfacetreatment.

Aspect (50) of this disclosure pertains to the vehicle interior systemof Aspect (49), wherein the surface treatment covers at least a portionof the first major surface and the second major surface.

Aspect (51) of this disclosure pertains to the vehicle interior systemof Aspect (49) or Aspect (50), wherein the surface treatment comprisesany one of an easy-to-clean surface, an anti-glare surface, ananti-reflective surface, and a pigment design.

Aspect (52) of this disclosure pertains to the vehicle interior systemof Aspect (51), wherein the surface treatment comprises at least two ofany one of an easy-to-clean surface, an anti-glare surface, ananti-reflective surface, and a pigment design.

Aspect (53) of this disclosure pertains to the vehicle interior systemof Aspect (52), wherein the first major surface comprises the anti-glaresurface and the second major surface comprises the anti-reflectivesurface.

Aspect (54) of this disclosure pertains to the vehicle interior systemof Aspect (52), wherein the first major surface comprises theanti-reflective surface and the second major surface comprises theanti-glare surface.

Aspect (55) of this disclosure pertains to the vehicle interior systemof Aspect (52), wherein the first major surface comprises either one ofor both the anti-glare surface and the anti-reflective surface, and thesecond major surface comprises the pigment design.

Aspect (56) of this disclosure pertains to the vehicle interior systemof Aspect (52), wherein the pigment design is disposed on at least aportion of the periphery and the interior portion is substantially freeof the pigment design.

Aspect (57) of this disclosure pertains to the vehicle interior systemof any one of Aspects (51)-(56), wherein the pigment design comprisesany one of a wood-grain design, a brushed metal design, a graphicdesign, a portrait, and a logo.

Aspect (58) of this disclosure pertains to the vehicle interior systemof any one of Aspects (51)-(57), wherein the anti-glare surfacecomprises an etched surface, and wherein the anti-reflective surfacecomprises a multi-layer coating.

Aspect (59) of this disclosure pertains to the vehicle interior systemof any one of Aspects (35)-(58), further comprising touch functionality.

Aspect (60) of this disclosure pertains to the vehicle interior systemof any one of Aspects (35)-(59), wherein the base comprises any one of acenter console, a dashboard, an arm rest, a pillar, a seat back, a floorboard, a headrest, a door panel, and a steering wheel.

Aspect (61) of this disclosure pertains to the vehicle interior systemof any one of Aspects (35)-(60), wherein the vehicle is any one of anautomobile, a seacraft, and an aircraft.

Aspect (62) of this disclosure pertains to the vehicle interior systemof any one of Aspects (35)-(61), wherein the second radius of curvatureis disposed in an area of the second major surface that is opposite toan area of the first major surface at which the adhesive has an elevatedadhesive stress.

Aspect (63) of this disclosure pertains to the vehicle interior systemof Aspect (62), wherein the elevated adhesive stress is above an averageadhesive stress of the adhesive over an area of the first major surfaceof the cold-formed glass substrate.

Aspect (64) of this disclosure pertains to the vehicle interior systemof Aspect (62), wherein the elevated adhesive stress is an area ofmaximum adhesive stress in the adhesive over an area of the first majorsurface.

Aspect (65) of this disclosure pertains to the vehicle interior systemof Aspect (62), wherein the elevated adhesive stress is an area of alocal maximum adhesive stress in the adhesive over an area of the firstmajor surface.

Aspect (66) of this disclosure pertains to a vehicle interior systemcomprising a base having a curved surface; a glass substrate disposed onthe curved surface, the glass substrate comprising a first majorsurface, a second major surface opposing the first major surface andfacing the curved surface, and a minor surface connecting the firstmajor surface and the second major surface, a thickness defined as adistance between the first major surface and the second major surface, awidth defined as a first dimension of one of the first or second majorsurfaces orthogonal to the thickness, and a length defined as a seconddimension of one of the first or second major surfaces orthogonal toboth the thickness and the width; and an adhesive disposed between thecurved surface and the glass substrate, wherein the thickness is 1.5 mmor less, wherein the second major surface comprises a first area havinga cold-formed curved surface including a first radius of curvature of500 mm or greater, and wherein the second major surface comprises asecond area having a hot-formed curved surface including a second radiusof curvature.

Aspect (67) of this disclosure pertains to the vehicle interior systemof Aspect (66), further comprising a display module attached to thefirst major surface and comprising a third radius of curvature that iswithin 10% of the first radius of curvature.

Aspect (68) of this disclosure pertains to the vehicle interior systemof Aspect (66) or Aspect (67), wherein the width is in a range fromabout 5 cm to about 250 cm, and the length is from about 5 cm to about250 cm.

Aspect (69) of this disclosure pertains to the vehicle interior systemof any one of Aspects (66)-(68), wherein the cold-formed glass substrateis strengthened.

Aspect (70) of this disclosure pertains to the vehicle interior systemof any one of Aspects (67)-(69), wherein the adhesive is disposedbetween the glass substrate and the display module.

Aspect (71) of this disclosure pertains to the vehicle interior systemof any one of Aspects (66)-(70), wherein the adhesive is opticallyclear.

Aspect (72) of this disclosure pertains to the vehicle interior systemof Aspect (66) or Aspect (67), wherein the glass substrate comprises aperiphery adjacent the minor surface, and the adhesive is disposedbetween the periphery of the second major surface and the displaymodule.

Aspect (73) of this disclosure pertains to the vehicle interior systemof any one of Aspects (66)-(72), wherein the display module comprises asecond glass substrate and a backlight unit, wherein the second glasssubstrate is disposed adjacent the first major surface and between thebacklight unit and the first major surface, and wherein the backlightunit is optionally curved to exhibit the second radius of curvature.

Aspect (74) of this disclosure pertains to the vehicle interior systemof Aspect (73), wherein the second glass substrate comprises acold-formed second glass substrate.

Aspect (75) of this disclosure pertains to the vehicle interior systemof Aspect (73) or Aspect (74), wherein the display module furthercomprises a frame at least partially surrounding the backlight unit.

Aspect (76) of this disclosure pertains to the vehicle interior systemof Aspect (75), wherein the frame at least partially surrounds thesecond glass substrate.

Aspect (77) of this disclosure pertains to the vehicle interior systemof Aspect (75) or Aspect (76), wherein the frame at least partiallysurrounds the minor surface of the glass substrate.

Aspect (78) of this disclosure pertains to the vehicle interior systemof Aspect (75) or Aspect (76), wherein the minor surface of the glasssubstrate is not surrounded by the frame.

Aspect (79) of this disclosure pertains to the vehicle interior systemof Aspect (75), wherein the frame comprises an L-shape.

Aspect (80) of this disclosure pertains to the vehicle interior systemof any one of Aspects (66)-(79), wherein either one of or both the firstmajor surface and the second major surface comprises a surfacetreatment.

Aspect (81) of this disclosure pertains to the vehicle interior systemof Aspect (80), wherein the surface treatment covers at least a portionof the first major surface and the second major surface.

Aspect (82) of this disclosure pertains to the vehicle interior systemof Aspect (80) or Aspect (81), wherein the surface treatment comprisesany one of an easy-to-clean surface, an anti-glare surface, ananti-reflective surface, and a pigment design.

Aspect (83) of this disclosure pertains to the vehicle interior systemof Aspect (82), wherein the surface treatment comprises at least two ofany one of an easy-to-clean surface, an anti-glare surface, ananti-reflective surface, and a pigment design.

Aspect (84) of this disclosure pertains to the vehicle interior systemof Aspect (83), wherein the first major surface comprises the anti-glaresurface and the second major surface comprises the anti-reflectivesurface.

Aspect (85) of this disclosure pertains to the vehicle interior systemof Aspect (83), wherein the first major surface comprises theanti-reflective surface and the second major surface comprises theanti-glare surface.

Aspect (86) of this disclosure pertains to the vehicle interior systemof Aspect (83), wherein the first major surface comprises either one ofor both the anti-glare surface and the anti-reflective surface, and thesecond major surface comprises the pigment design.

Aspect (87) of this disclosure pertains to the vehicle interior systemof Aspect (83), wherein the pigment design is disposed on at least aportion of the periphery and the interior portion is substantially freeof the pigment design.

Aspect (88) of this disclosure pertains to the vehicle interior systemof any one of Aspects (82)-(87), wherein the pigment design comprisesany one of a wood-grain design, a brushed metal design, a graphicdesign, a portrait, and a logo.

Aspect (89) of this disclosure pertains to the vehicle interior systemof any one of Aspects (82)-(88), wherein the anti-glare surfacecomprises an etched surface, and wherein the anti-reflective surfacecomprises a multi-layer coating.

Aspect (90) of this disclosure pertains to the vehicle interior systemof any one of Aspects (66)-(89), further comprising touch functionality.

Aspect (91) of this disclosure pertains to the vehicle interior systemof any one of Aspects (66)-(90), wherein the base comprises any one of acenter console, a dashboard, an arm rest, a pillar, a seat back, a floorboard, a headrest, a door panel, and a steering wheel.

Aspect (92) of this disclosure pertains to the vehicle interior systemof any one of Aspects (66)-(91), wherein the vehicle is any one of anautomobile, a seacraft, and an aircraft.

Aspect (93) of this disclosure pertains to the vehicle interior systemof any one of Aspects (66)-(92), wherein the second radius of curvatureis smaller than the first radius of curvature.

Aspect (94) of this disclosure pertains to the vehicle interior systemof any one of Aspects (66)-(93), wherein the second radius of curvatureis less than 500 mm.

Aspect (95) of this disclosure pertains to the vehicle interior systemof Aspect (94), wherein the second radius of curvature is about 100 mmor less.

Aspect (96) of this disclosure pertains to a method of forming a curvedvehicle interior component comprising: hot-forming a first area of aglass substrate having a first major surface and a second major surfaceopposite the first major surface to a first radius of curvature asmeasured on the second major surface; and cold-forming a second area ofthe glass substrate to a second radius of curvature as measured on thesecond major surface, the second area being different than the firstarea.

Aspect (97) of this disclosure pertains to the method of Aspect (96),further comprising laminating a display module to the first majorsurface while maintaining the second radius of curvature in the glasssubstrate to form a curved display, wherein the display module has athird radius of curvature that is within 10% of the second radius ofcurvature.

Aspect (98) of this disclosure pertains to the method of Aspect (96),wherein cold-forming the glass substrate comprises applying a vacuum tothe second major surface to generate the second radius of curvature.

Aspect (99) of this disclosure pertains to the method of Aspect (97),wherein applying the vacuum comprises placing the glass substrate on avacuum fixture before applying the vacuum to the second major surface.

Aspect (100) of this disclosure pertains to the method of any one ofAspects (96)-(98), further comprising laminating an adhesive to thefirst major surface before laminating the display module to the firstmajor surface such that the adhesive is disposed between the first majorsurface and the display module.

Aspect (101) of this disclosure pertains to the method of any one ofAspects (96)-(100), wherein laminating a display module compriseslaminating a second glass substrate to the glass substrate; andattaching a backlight unit to the second glass substrate, wherein thebacklight unit is optionally curved to exhibit the third radius ofcurvature.

Aspect (102) of this disclosure pertains to the method of Aspect (101),wherein laminating the second glass substrate comprises cold-forming thesecond glass substrate.

Aspect (103) of this disclosure pertains to the method of Aspect (101)or Aspect (102), further comprising attaching a frame with the backlightunit to the second glass substrate.

Aspect (104) of this disclosure pertains to the method of any one ofAspects (101)-(103), wherein the adhesive is disposed between the secondglass substrate and the glass substrate.

Aspect (105) of this disclosure pertains to the method of any one of anyone of Aspects (97)-(104), further comprising removing the vacuum fromthe second major surface.

Aspect (106) of this disclosure pertains to the method of Aspect (105),wherein removing the vacuum from the second major surface comprisesremoving the curved display from the vacuum fixture.

Aspect (107) of this disclosure pertains to the method of any one ofAspects (95)-(106), wherein the glass substrate has a thickness of about1.5 mm or less.

Aspect (108) of this disclosure pertains to the method of any one ofAspects (95)-(107), wherein the glass substrate is strengthened.

Aspect (109) of this disclosure pertains to the method of any one ofAspects (101)-(108), wherein the second glass substrate isunstrengthened.

Aspect (110) of this disclosure pertains to the method of any one ofAspects (101)-(109), wherein the second glass substrate has a thicknessthat is greater than a thickness of the glass substrate.

Aspect (111) of this disclosure pertains to the method of any one ofAspect (96)-(110), wherein the second radius of curvature is in a rangefrom about 60 mm to about 1500 mm.

Aspect (112) of this disclosure pertains to the method of any one ofAspects (99)-(111), wherein the adhesive has a thickness of about 1 mmor less.

Aspect (113) of this disclosure pertains to the method of any one ofAspects (96)-(112), further comprising disposing the curved display in avehicle interior system.

Aspect (114) of this disclosure pertains to the method of any one ofAspects (96)-(113), wherein the first radius of curvature is less thanthe second radius of curvature.

Aspect (115) of this disclosure pertains to the method of any one ofAspects (96)-(114), wherein the first radius of curvature is about 100mm or less.

Aspect (116) of this disclosure pertains to the method of any one ofAspects (96)-(115), wherein the hot-forming of the first area occursbefore the cold-forming of the second area.

Aspect (117) of this disclosure pertains to the method of any one ofAspects (96)-(116), further comprising treating at least one of thefirst major surface and the second major surface with a surfacetreatment after the hot-forming.

Aspect (118) of this disclosure pertains to the method of Aspect (117),wherein the surface treatment covers at least a portion of the firstmajor surface and the second major surface.

Aspect (119) of this disclosure pertains to the method of Aspect (117)or Aspect (118), wherein the surface treatment comprises at least one ofan easy-to-clean surface, an anti-glare surface, an anti-reflectivesurface, and a pigment design.

Aspect (120) of this disclosure pertains to the method of any one ofAspects (96)-(119), wherein, during cold-forming, a maximum temperatureof the glass substrate is less than a glass transition temperature ofthe glass substrate.

It will be apparent to those skilled in the art that variousmodifications and variations can be made without departing from thespirit or scope of the invention.

What is claimed is:
 1. A vehicle interior system comprising a basehaving a curved surface; a cold-formed glass substrate disposed on thecurved surface, the glass substrate comprising a first major surface, asecond major surface opposing the first major surface and facing thecurved surface, and a minor surface connecting the first major surfaceand the second major surface, a thickness defined as a distance betweenthe first major surface and the second major surface, a width defined asa first dimension of one of the first or second major surfacesorthogonal to the thickness, and a length defined as a second dimensionof one of the first or second major surfaces orthogonal to both thethickness and the width; an adhesive disposed between the curved surfaceand the glass substrate; and at least one stress-reduction component ina location that reduces an amount of adhesive stress in one or moreareas of the adhesive; wherein the thickness is 1.5 mm or less, thewidth is in a range from about 5 cm to about 250 cm, and the length isfrom about 5 cm to about 250 cm wherein the at least onestress-reduction component comprises a hot-formed portion of thecold-formed glass substrate proximate to the minor surface, and whereinthe second major surface comprises a first radius of curvature of 500 mmor greater.
 2. The vehicle interior system of claim 1, furthercomprising a display module attached to the first major surface andcomprising a second radius of curvature that is within 10% of the firstradius of curvature.
 3. The vehicle interior system of claim 2, whereinthe adhesive is disposed between the glass substrate and the displaymodule.
 4. The vehicle interior system of claim 1, wherein the glasssubstrate comprises a periphery adjacent the minor surface, and theadhesive is disposed between the periphery and the curved surface. 5.The vehicle interior system of claim 4, wherein the glass substratecomprises a cold-formed portion that is cold-formed to the curvedsurface such that the portion is held by the adhesive in a bent shapedespite there being elastic stresses in the cold-formed portion.
 6. Thevehicle interior system of claim 5, wherein the adhesive stress isgenerated due to the elastic stresses in the cold-formed portion.
 7. Thevehicle interior system of claim 6, wherein the cold-formed portion iscold-formed to comprise a global radius of curvature of 500 mm or more.8. The vehicle interior system of claim 7, wherein the hot-formedportion comprises a local radius of curvature that is less than theglobal radius of curvature.
 9. The vehicle interior system of claim 8,wherein the local radius of curvature is less than or equal to 100 mm.10. The vehicle interior system of claim 8, wherein the first majorsurface comprises a concave shape in the cold-formed portion and aconvex shape in the hot-formed portion.
 11. The vehicle interior systemof claim 1, wherein the thickness is greater than or equal to 0.7 mm andless than or equal to 1.5 mm.
 12. The vehicle interior system of claim11, wherein the adhesive comprises a thickness that is greater than orequal to 200 μm and less than or equal to 500 μm.
 13. The vehicleinterior system of claim 12, wherein the adhesive comprises a pressuresensitive structural adhesive.
 14. A vehicle interior system comprisinga base having a curved surface; a cold-formed glass substrate disposedon the curved surface, the glass substrate comprising a first majorsurface, a second major surface opposing the first major surface andfacing the curved surface, and a minor surface connecting the firstmajor surface and the second major surface, a thickness defined as adistance between the first major surface and the second major surface, awidth defined as a first dimension of one of the first or second majorsurfaces orthogonal to the thickness, and a length defined as a seconddimension of one of the first or second major surfaces orthogonal toboth the thickness and the width, wherein the thickness is greater thanor equal to 0.5 mm and less than or equal to 1.5 mm; an adhesivedisposed between the curved surface and the glass substrate at aperiphery of the cold-formed glass substrate adjacent to the minorsurface, wherein the adhesive holds a cold-formed portion of the glasssubstrate in an elastically bent state such that there are stresses inthe adhesive; and at least one stress-reduction component configured toalleviate the stresses in the adhesive, wherein: the at least onestress-reduction component comprises a hot-formed portion of thecold-formed glass substrate proximate to the minor surface, and whereinthe second major surface comprises a first radius of curvature of 500 mmor greater.
 15. The vehicle interior system of claim 14, furthercomprising a display module attached to the first major surface andcomprising a second radius of curvature that is within 10% of the firstradius of curvature.
 16. The vehicle interior system of claim 15,wherein the adhesive is disposed between the glass substrate and thedisplay module.
 17. The vehicle interior system of claim 14, wherein thecold-formed portion is cold-formed to comprise a global radius ofcurvature of 500 mm or more.
 18. The vehicle interior system of claim17, wherein the hot-formed portion comprises a local radius of curvaturethat is less than the global radius of curvature.
 19. The vehicleinterior system of claim 18, wherein the local radius of curvature isless than or equal to 100 mm.
 20. The vehicle interior system of claim18, wherein the first major surface comprises a concave shape in thecold-formed portion and a convex shape in the hot-formed portion.